Modular Power Plant ETS-W1560 1.25 MW

Features of the new GRPP

The design of ЭТС-W1560 GRPP reaffirms ETS-Astana LLC’s dedication to its core design principles: maintaining compactness, high factory readiness, versatility, and ease of maintenance. At the same time, it retains its mobility. The dimensions of the initial ЭТС-W1560 units in operational condition, with all attachments installed, are 10500 x 2400 x 6200 mm. This represents a reduction of 1.5 meters in length compared to ЭТС-W1375, while maintaining the same height and width.

The reduced dimensions were made achievable through optimized layout solutions and the utilization of a gas genset from the new, “fifth” series, offering increased power output. Meanwhile, the engine dimensions remained unchanged compared to the previous version. It might be assumed that the engine began operating in a more intense mode, resulting in increased load on its individual components. However, this is not the case. On the contrary, the engine became less loaded. This was achieved through several factors: firstly, the adoption of enriched fuel mixture burning technology based on the Miller cycle; secondly, modifications to the cylinder head design to decrease temperatures in critical zones; and thirdly, optimization of the piston design.

These technical innovations guarantee high performance characteristics for ЭТС-W1560 GRPP:

1. High fuel versatility.

ЭТС-W1560 GRPP can operate stably on complex gases. The engine operates at full power even with gas compositions rated WKI* 55 and higher. The engine’s lifespan remains largely unaffected even in the presence of sulfur-containing components in the fuel gas, up to 0.2% molar fraction.

2. Capability to operate effectively in environments characterized by high ambient temperatures and at high altitudes

ЭTC-W1560 can maintain its power output even in hot regions at high altitudes above sea level. ЭTC-W1560 can operate without derating within specified limits: ambient temperatures up to +40°C and altitudes up to 1000 meters above sea level. Even at altitudes exceeding 1000 meters and under higher temperatures, ЭТС-W1560 GRPP remains operational, albeit with a slight reduction in output power.

3. Low operating costs.

Despite its higher power output compared to ЭТС-W1375, the operating costs of the new gas reciprocating power plant have decreased by 22%. Achieving such results was made possible thanks to the following factors:

• Utilizing less expensive spark plugs with an increased lifespan.

Employing base metal spark plugs and a new generation ignition power module (IPMD2) extends the spark plug replacement interval to 4000 hours.

• Extended oil change intervals.

The improved piston design has extended oil change intervals to 4000 operating hours. The need for replacement depends on the gas composition and operating conditions and is determined by the actual condition.

• Reducing the number of service team visits for engine maintenance, resulting in lower operating costs.

4. Extended intervals for major maintenance.

One notable advantage of employing the Miller cycle in the combustion process is the decrease in temperature at the end of the compression stroke. While a lower temperature might suggest a longer service interval, the designers didn’t stop there. New cylinder heads were specially developed with XCOOLED cooling technology, featuring optimized coolant flow. This innovation further reduces the temperature at individual points of the valve group by 10 to 40%.

Furthermore, ЭТС-W1560 gas engine employs a piston design with a reduced piston crater volume, resulting in a temperature reduction of up to 50°C in the upper ridge of the piston. These design enhancements have significantly increased the service life of the cylinder head, now ranging from 24,000 to 30,000 hours.

It’s worth noting that the Miller cycle requires more intense boosting than a traditional engine running on a rich fuel mixture. To achieve such a boost, the engine utilizes a new powerful turbocharger, constructed with materials exhibiting higher strength characteristics compared to ЭТС-W1375. This enhancement allows for an increased service life ranging from 24,000 to 30,000 hours.

5. Ease of management and troubleshooting.

Similar to its predecessor, ЭТС-W1560 employs the new generation ESM2 motor controller, featuring a sizable resistive touch screen. Interaction with the controller is versatile, including touch input from fingers, gloves, or styluses, as the screen is responsive to pressure from any object. Previously, accessing precise settings or diagnostics required the use of a separate laptop or computer. Now the touch screen allows full interaction with all systems. The new controller functions are highlighted below:

• Full-color display of engine operating parameters graphically represented;
• Display of all faults, along with a built-in step-by-step troubleshooting module;
• Control of exhaust and main bearing temperatures, as well as oil pressure;
• Misfire control.

Furthermore, ESM2 offers integration capabilities with myPlant platform.

Trial operation of engines similar to those utilized in ЭТС-W1560 GRPP has demonstrated unparalleled reliability, reaching an impressive level of 99.8%. Experimental tests were conducted from 2017 to 2019 on three units operating at a load range of 90% to 100% of their rated capacity.

For each model, engineers have developed an individual design of the power frame on which the engine and generator are installed. ETS-Astana selects reliable solutions from the Stamford generator line by Cummins Generator Technologies (CGT) for pairing with the engine during installation. For ЭТС-W1560 model, the generator was specifically developed by CGT to meet the technical requirements of the new gas reciprocating power plant.

Innovations in engineering systems of gas reciprocating power plants

The ventilation and cooling system of the power unit in ЭТС-W1560 GRPP has undergone significant modernization compared to the previous model. The initial versions of ЭТС-W1560 GRPP incorporate an air supply module, securely installed on the roof of the main unit. All systems housed within the upper module do not necessitate disassembly to convert it to the transportable condition; requisite flanges and connectors are provided for their connection. Hence, installing this module on-site will not demand much time.

The supply module incorporates G3 class filters, which effectively block small particles like pollen from entering the container while also drying the incoming air. This means that the standard air filter at the GRU inlet will have an extended lifespan. Furthermore, ЭТС-W1560 GRPP incorporates air recirculation. The supply module also facilitates the mixing of hot exhaust air with cold air from the outside. This solution enhances the reliability of power plant operation in low-temperature conditions.

Aero- and thermodynamic calculations facilitated precise simulation of airflow within the turbine room. Measurements conducted during trial operation, combined with accumulated experience from operating equipment of similar models, aided in optimally distributing the airflow to achieve efficient heat removal from the operating installation.

The ventilation system is managed by a dedicated electronic module that analyzes data from both the engine control system and various sensors positioned both inside and outside the container. Airflows within the module are strategically distributed to prevent direct contact of the cold airflow with the engine housing, thereby mitigating potential damage from temperature fluctuations.

Similar to ЭТС-W1375, the new gas reciprocating power plant has a separate ventilated compartment for the dry transformer. The transformer’s high-side voltage is adjusted by altering the winding connection configuration. Thus, the versatility of the solution is ensured: The gas reciprocating power plant can be employed in networks with voltages of 0.4 kV (without requiring a transformer), as well as 6.3 or 10.5 kV (using a transformer).

Additionally, significant efforts have been made by the company to enhance the weight and size characteristics of ЭТС-W1560 GRPP. Strength calculations enabled the identification of lightly loaded sections of the module, allowing for optimization of their metal consumption while preserving the load-bearing capacity of the structure. Conversely, heavily loaded elements, particularly in areas above or below doorways, are reinforced with beams of increased cross-section and thicker metal. The company assures that even after 10–15 years, when the load-bearing structures inevitably undergo corrosion, the module will maintain its original rigidity. This implies that the gas reciprocating power plant can be relocated to a new site at any point during its entire lifecycle.

We also emphasize strict adherence to transportation dimensions. Frequently, the inclusion of remote elements such as signal signs, lamps, fastening points, gland boards, etc., results in the container’s dimensions slightly exceeding permissible limits during transportation. These additional centimeters can sometimes complicate the transportation of the module on public roads. In ЭТС-W1560 GRPP, all external elements are integrated into the module, recessed into separate niches.

Among the proven servicing solutions for gas engines, which are also implemented in ЭТС-W1375, the following are noteworthy:

• the delivery package includes a service platform equipped with a shelter. It is installed within the opening of double doors and serves to facilitate the execution of service tasks in adverse weather conditions. Its spacious design accommodates a specialist along with a full set of specialized tools and spare parts.
• two overhead cranes with a lifting capacity of 500 kg, equipped with hoists and mechanisms for hoist movement, are included as standard equipment.
• one of the end walls of the gas reciprocating power plant is designed to be removable, facilitating easy removal of the gas engine for major repairs.

ЭТС-W1560, the new model of gas reciprocating power plant from ETS-Astana, is expected to find significant demand in projects utilizing complex fuel gases. It is anticipated to be utilized in providing power supply to O&G fields with surplus methane-containing gases for disposal, as well as other facilities, especially those situated in hot climatic zones and mountainous regions such as the southern areas of Qazaqstan, Tajikistan, Uzbekistan, Kyrgyzstan, and beyond.

*WKI, which stands for Waukesha Knock Index and serves as an equivalent to the methane number (MN), is employed by Waukesha for assessing engine performance with different fuel gases. Depending on the composition of the fuel gas, it may be numerically equivalent to or slightly higher than the methane number (MN) calculated for the same composition using the AVL method.