Project reinforces WEG’s capacity by supplying solutions for the water industry
Producing clean energy and taking advantage of the hydraulic potential of a river is the main role of hydroelectric power plants. In order to allow them to operate efficiently and safely, a set of quality and reliable equipment built for long continuous operating periods is required. To guarantee the success of this project’s operation, WEG was selected to supply the hidrogenerators for São Roque Hydroelectric Power Plant, located in the municipality of Vargem, the state of Santa Catarina, in Brazil.
Regarded as one of the most important project components, WEG´s package includes three 50.5 MVA, 13.8 kV and 180 rpm SLW 4000 hydrogenerators and the auxiliary equipment.
Weighing 285 tons each and approximately eight meters in diameter, these machineries are the largest electric hydrogenerators ever produced by WEG.With specialized engineering and verticalized production, WEG designs and produces equipment that fully meets our customer’s needs and requirements.
This supply is part of a large infrastructure project that will provide energy for Brazil´s electric system, boosting the region and the country´s economic sector. Dependent on 142 megawatts of installed capacity, the São Roque Power Plant generates enough energy to supply a city with approximately 170 thousand people.
The use of a ball mill in the grinding process is a traditional technique widely used for particle size reduction or for mixing materials, used in various industrial works, such as mining companies. In this sense, because it is a more severe environment, it is necessary to use a motor with greater resistance and protection.
With efficient solutions in the mining sector, WEG supplied a slip ring motor from the M Mining line, frame 560, 1,300 kW, 3,300 V, 4 poles, 50 Hz to drive the ball mill of a mining company in Argentina. The applied motor makes the process more efficient, ensuring greater operational security, in addition to having simple and reduced maintenance.
WEG motors of the M Mining line were specially developed with electromechanical characteristics that provide durability, resistance and robustness, ideal for operating in harsh environments in the mining and cement segment. The big difference in this project is that to reduce the need for field adjustments, WEG adapted the manufacturing process to scale the solution according to the customer’s needs.
This supply consolidates WEG as one of the main suppliers of motors for the mining segment in Latin America, in addition to reinforcing the company’s flexibility in meeting the specific needs of its customers. For the customer, it increases reliability in operation and reduces downtime for maintenance.
The new brush lifting system is the evolution of the already established WEG brush lifting system, with the incorporation of the operating logic, fault investigation capabilities, operation monitoring via HMI simplifying and reducing the costs of motor installation, operation, and maintenance. In order to carry out the operation logic in a simpler way, its operation is via PLC. The monitoring of the operation and eventual faults is available via the integrated PLC’s display so that the user has full control over the performance of this system.
The need for maintenance compared to a fixed brush system reduces considerably, due to the brushes being lifted after the motor starts, in addition to allowing the elimination or reduction of several variables, such as:
The lifting set has a gearbox driving the operation, adding robustness, reliability, and simplicity to the system. The brush holder works with constant pressure springs and has three inspection points, allowing agility and visibility in preventive, predictive or corrective maintenance. The internal position of the lifting mechanism is read by means of inductive sensors and they have a system that indicates their operating status.
WEG is the supplier of the complete Utility Scale Lithium-ion Battery Energy Storage System for the green hydrogen generation study plant Furnas, installed at the Itumbiara Hydroelectric Power Plant, stated of Goiás and Minas Gerais.
Counting on an installed capacity of 300kW and 600kWh, BESS (Battery Energy Storage System) is part of the Research and Development (R&D) Project, regulated by the National Electric Energy Agency (Aneel), which will test the storage of seasonal and intermittent energies and their interaction with the National Interconnected System (SIN).
Named “Development of synergy between hydroelectric and solar sources with seasonal and intermittent energy storage in hydrogen and electrochemical systems – SHSBH2”, this R&D project is the result of a partnership between Furnas and the company Base Energia Sustentável, associated with Unesp (State University of São Paulo); Unicamp (University of Campinas); Senai (National Service for Industrial Learning); Brandenburg University (Germany) – academic institution with experience in hydrogen storage; and PV Solar, a partner company experienced in implementing photovoltaic systems.
“Participating in a pioneering green hydrogen generation project is a great opportunity to show our expertise to meet the growing market of energy storage by batteries, also in Brazil”, says Manfred Peter Johann, WEG Automation Business Unit Managing Director.
The first stage consisted of installing a photovoltaic plant with a capacity to produce 1000 kWp (peak kilowatts, a power unit associated to photovoltaic energy). From this total amount, 200 kWp will come from floating solar plates on the reservoir and 800 kWp from solar plates installed on the ground. Itumbiara HPP was chosen to be the location for the project due to the good rates for solar generation and for allowing an adequate storage reservoir for the installation of floating photovoltaic panels.
The energy generated by the photovoltaic system feeds an electrolyser that produces hydrogen from a physical-chemical process with water. The hydrogen is then stored in the form of gas, in a tank with a capacity of 900 cubic meters at 27 bar, installed in the plant. For conversion of chemical energy contained in hydrogen into electrical energy a fuel cell is used. The result of the conversion is electricity and water steam.
In addition to hydrogen, the project also allows research of electrochemical storage into lithium batteries. Used in this project to support the startup of the hydrogen plant and provide energy reserve (backup) for eventual failures, lithium batteries also ensure fast energy supply during load fluctuations.
Hydrogen storage usually provides longer performance time, but efficiency is still reduced – around 35%, against 97% for batteries. This occurs due to the losses in electrolysis and conversion into electricity. Tests in Itumbiara will evaluate the electrolyser technology, the maintenance cost, the equipment lifetime, the efficiency losses resulting from system wear, the quality of stored energy and the response time when it is interacted with the National Interconnected System, among other aspects. These analyzes can provide essential information for the development of large projects. FURNAS is a pioneer about these studies.
The energy will be integrated into the National Interconnected System (SIN) through the substation installed at Itumbiara HPP and will be used for supporting hydroelectric power services, such as lighting, ventilation and others.
In June 2021, WEG completed the supply of the WestRock Paper Mill Expansion Project, in Três Barras, state of Santa Catarina. The solution package included a 59 MVA turbogenerator, e-Houses, low and medium voltage MCCs, frequency inverters, W22 WELL (WEG Extra Long Life), W50 and W60 motors, dry type transformers and field services.
The technical requirements demanded by the American company were ensured by WEG with integrated and customized solutions. With the capability to supply turn-key solutions from the beginning to the end of the production process, WEG is the ideal partner for those seeking efficiency. In addition, WEG provides customers with a complete after-sales support to ensure the full operational functioning of the electrical equipment.
Concerned about the technical requirements, WestRock, a company that owns the largest kraftliner paper mill in Latin America, chose WEG as a supplier for the optimization and expansion of its production capacity. With this expansion, production increased from 480 thousand to 750 thousand tons per year and the factory’s self-sufficiency in energy increased by 30%.
After feasibility analysis, WestRock chose for WELL (WEG Extra Long Life) motor’s technology that meet the reliability requirements demanded by the segment. The longer life time as well as lower maintenance of these motors are characteristics that directly impact the plant’s efficiency.
The great challenge of this project was the interchangeability of the new equipment and the service provided without interrupting the operations of the existing plant.
Reliability and trust are delivered by WEG with its broad portfolio available to the market. For the pulp and paper segment, the company has complete solutions, ranging from the supply of high efficiency motors to the most advanced automation systems, including the entire electrical infrastructure and power generation. They are innovative solutions that increase performance and improve the quality of customer’s product.
For Greenfield or Brownfield projects in the pulp and paper segment, count on WEG. For more information, click here. Please visit: https://www.weg.net/institutional/US/en/solutions/pulp-paper
WEG has just announced that the company is one of Marcopolo’s partners for the development of Attivi, which is the first electric bus manufactured with its own chassis.
In operation since October in the city of São Paulo, on an experimental basis, this is a 13.25 meters long standard bus with capacity for 89 passengers (sitting and standing) and autonomy of about 250 kilometers. Marcopolo Attivi is equipped with a WEG Powertrain consisting of a 395 kW and 2800 Nm of torque three-phase motor and a frequency drive. In line with environmental protection principles, the plan is to adapt this vehicle to the demands for urban and intercity transports.
Developed in Brazil, with national and imported technology, Attivi is a milestone for global electric mobility, according to Manfred Peter Johann, WEG Automation Business Unit Director. “We are leading the national electric mobility market with predominantly Brazilian technology, tested, approved and continually updated. Together with Marcopolo and other important electrification chain suppliers, we are able to build a strategic niche, with strong industrial technology, capable of meeting national demand and selling all over the world”, says Manfred. In addition to bringing together all the expertise that WEG and Marcopolo have in the production of mobility solutions, Attivi ensures zero CO2 emission, meeting global safety standards.
“There is a favorable market background in Brazil for the development of electric-powered transport, with energy providers willing to invest in the system. In addition to the environmental benefit, electric mobility has a lower operating cost compared to diesel and its adoption tends to be decisive for a sustainable future”, says James Bellini, CEO of Marcopolo.
The new model is already being tested and will be exhibited during the 18th National Science and Technology Week, which will take place in Brasília from December 3rd to 10th.
Founded 72 years ago in the city of Caxias, state of Rio Grande do Sul, Marcopolo is the leader in the manufacture of bus bodies in Brazil and ranks among the largest manufacturers in the world.
The company continually invests in product innovation, technology, design and expansion, producing solutions that contribute to the development of public transport for passengers and the future of mobility.
With factories located on five continents, the vehicles produced by the company has established a global presence in over 100 countries.
One of the two six-meter containerized substations being supplied to the Tetra4 onshore natural gas and helium project.
Developed by emerging producer Renergen, Tetra4 is the country’s first and only holder of an onshore petroleum production right. Located near Virginia in the Free State province, the natural gas in the deposit reportedly contains world-beating concentrations of helium – up to 12% compared to typical levels of around 0,5%.
The first phase of the project is advancing well, with the construction of the liquid natural gas (LNG) and helium plant scheduled for completion by the end of 2021 or early in 2022.
According to Lukas Barnard, Zest WEG’s sector specialist – oil and gas business development, the equipment ordered from Zest WEG is on track to be delivered and installed in the third quarter of this year.
“The transformers we have been contracted to supply are a 7MVA 33/11KV unit and two 1.5MVA 6.6/0.4KV units, being manufactured locally at our transformer facility in Wadeville,” says Barnard. “We will also supply the 33kV, 11kV and 6,6kV medium voltage switchgear, which will be installed into two six-meter containerized substations, being locally manufactured by Zest WEG at its Heidelberg facility.”
“The medium voltage switchgear will be installed in the modular substations in Heidelberg, where a factory acceptance test will be conducted before equipment is transported to site,” he says. “The complete package is managed with a single point of contact – a project manager – at Zest WEG, easing the customer’s administrative burden.”
Renergen says it wanted a supplier with the necessary experience and expertise, but more than that it needed a partner who could meet the tight delivery requirements, with enough flexibility to find solutions to the challenges related to a project of this nature.
“There have been many benefits working with local companies including additional flexibility and control, while allowing us to react quickly to changes and challenges that arise as we roll out the project,” says Nick Mitchell, Renergen Chief Operating Officer.
“Any support of local business has far reaching economic benefits for the communities in which they operate and this remains a critical balance for us to achieve in a project, where not all the components can be manufactured locally or available locally. It also reduces currency risk by minimizing our exposure to exchange rate fluctuations.”
Renergen also emphasizes the advantage of Zest WEG’s package solutions capability, especially in a project like this with multiple streams of work that need to be coordinated across multi-disciplinary teams. Barnard says this is where Zest WEG’s project manager added considerable value in terms of management, procurement and project flow.
“When multiple contractors and suppliers are involved, the project flow becomes very difficult and can generate significantly more risk,” he says. “Our project manager was able to work with the customer to mitigate these risks and streamline the roll-out.”
He also notes the advantages of the containerized and E-House modular substations in fast track projects. By manufacturing the units in a dedicated facility, Zest WEG provided an efficient solution while reducing the on-site responsibilities of the project developers.
“Building a brick-and-mortar substation means more personnel and activity on site over an extended period, with all the related health and safety implications such as inductions and medical checks,” says Barnard. “It is quicker and far more convenient to build it in a well-equipped facility such as ours where it is also possible to run factory acceptance tests before delivery.”
Howden South America, in partnership with WEG, are supplying the refrigeration project (phase 1) for Caraíba Mine in Jaguarari, state of Bahia, Brazil. Supported by Cooling System Howden technology, the project ensures safe and economical underground refrigeration. Howden counted on WEG’s key participation with emphasis on an E-house for a refrigeration and an electrical package to drive the plant from the initial engineering stage, to manufacturing, commissioning and start-up, including transport to the mine site.
In addition to the W22Mining super premium electric motors, the WEG solution included a 2500 kVA dry transformer, a complete ELW Mining E-house with auxiliary Wall Mounted air conditioning systems, fire protection and other internal circuit as well as an intelligent CCM06 that includes CFW11 frequency drive, Enterprise nobreak and automation system with PLC panel. The solution provided by WEG in partnership with Howden brought together the technical teams of both companies and reduced the time required for electrical interconnections and equipment start-up since the E-house is supplied with all internal interconnections and fully tested at the factory.
Howden Sales Director, Edson Luis Geraldini, stated that the Howden and WEG partnership represents a significant drop in the internal temperature, in a 1400-meter deep mine with 105 kilometers of galleries and 8400 meters of ramps thus providing a more pleasant environment for the workers. At the same time, the equipment for the second phase of the project for the new mines that are part of the Caraíba Mine industrial complex are already in production at WEG with operation expected for the first quarter of 2022.
Four substations located in Barranquilla, which are scheduled for commissioning in the coming months, will be supplied with seven WEG transformers, six of them in the range of 30MVA at 110kV, and one unit in the range of 50MVA at the same voltage. Regarded as essential for the substation operation, all transformers will be permanently connected.
This supply to INGEMA directly impacts the local development as the final customers AIR-E and AFINIA seek to improve the indicators and energy supply for the northern coast of Colombia, through the expansion of the capacity of energy transformation and distribution. Benefit of that is the improved reliability of the electricity grid.
“INGEMA is a key construction company in Colombia and this partnership opens the door for future WEG project negotiations, which will further strengthen our presence in the country and in Latin America. “Effective communication, values and professionalism define our partnership with WEG, in addition to having contributed to my knowledge and skills learning curve, bringing confidence and meeting expectations at every stage of the acquisition process. We thank WEG for being part of the electricity sector transformation on the Atlantic coast, benefiting and providing comfort to each of the Barranquilla residences” said Andrea Cantillo, INGEMA´s Electromechanical Coordinator.
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