Projects : Generator Replacement Electrical Engineering

Florida Crystals operates one of the largest sugar mills in the U.S. The plant burns sugar cane mulch to produce process steam used in the production of raw sugar. Excess steam is used in the production of 100MW of electricity that is sold to Florida Power and Light (FP&L). The co-generation facility went on line in 1994. Following electrical generator problems that necessitated a "re-wind", the generator unit soon experienced a catastrophic failure that resulted in a total loss of the generator. On behalf of Siemens-Westinghouse Power Corporation (SWPC), DPT provided electrical engineering and installation support necessary to replace the failed generator with a new 165 MVA machine met the owner’s tight restart schedule.

While modern machines are designed to match the existing plant duty conditions, the output and configuration of the new machine did not exactly match that of the failed unit since the new unit was destined for another installation. Consequently, modifications to various electrical items were required.

Installation of the new 165 MVA Generator Unit and 6000A Non-Segregated Bus

DPT engineers worked closely with SWPC engineers to ensure that the modifications to the existing protective scheme were properly made to provide proper coordination between the new generator, the plant distribution system and the FP&L switchyard interface. We also worked with local contractors to verify that new generator and system protective devices were properly set and that a new generator control system was functioning properly because the new unit had a different excitation system than the original. DPT provided oversight to the manufacture and installation of a new 6000A non-segregated bus that was installed from the generator to the generator breaker. The main leads of the replacement generator exited the unit 90° from the existing unit which required that DPT engineers design and oversee installation of a new main lead cubicle. Completion of the work allowed the unit to return to service approximately 10 weeks after the initial project authorization.

Projects:

Studies and Development

Site-Civil Development

Structural Engineering

Mechanical Engineering

Electrical Engineering

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