FG Wilson Support Cogeneration Power Station

Country: Ukraine
Industry Sector: Industry
Product(s): 2 x PG1250B
Application: Combined Heat and Power

FG Wilson support CHP station for glass plant

The largest glassware manufacturer in the Ukraine, the Gostomel Glass Plant in Kiev produces up to 1.5 million units per day for use in various industries, for both indigenous and export use.

Energy costs are a major concern for industries in the Ukraine accounting for 15% (average) of the total cost of goods sold each year by Gostomel.

Significant annual energy cost savings as well as a large reduction in energy consumption had been achieved through energy efficiency measures following an energy audit. Continuing these improvements, Gostomel, in partnership with Energy Alliance (Ukraine's first privately owned energy services company) commissioned a new natural gas fired cogeneration power station, enlisting the help of FG Wilson.

Designed and manufactured by FG Wilson, the cogeneration power station, comprises two FG Wilson PG1250B gas generating sets with integrated waste heat recovery modules. The complete power station produces a combined total output of 2000 kWatt/hour of electricity and 2.15 Gcal/hour of reclaimed heat doing so at a cost of $0.015/ kWh, an incredible three times less than the state energy company.

The project required two PG1250B gas generating sets each powered by a Perkins 4016 series electronic spark ignited gas engine and coupled to a Leroy Somer low voltage alternator. The sets were equipped with bespoke control systems for single and/or parallel use with a master synchronising PLC and with close remote monitoring and control. Waste heat from each engine jacket water and exhaust system is recovered by heat exchanger and smoke tube boiler modular systems.

Limited space and proximity to the local community meant the generating sets and heat recovery packages were installed in an existing boiler house. The cooling groups were completed with low noise multi fan radiators sited outside the building. The heat generated by the cogeneration units is supplied to residents of adjacent apartment buildings.

FG Wilson's Moscow office worked closely with Madek, the local FG Wilson Dealer in the Ukraine. Allied to this, FG Wilsons' renowned technical expertise and project management skills helped ensure the successful execution of this prestigious project.

Madek and Gostomel engineers installed and commissioned the plant having received training in the operation and aftercare of the equipment both at the FG Wilson factory in Larne and on site in Kiev.

Local and international dignitaries alongside members of the local business community attended the official opening of the upgraded plant. At the ceremony a senior Gostomel representative stated,

"Through this power station, we will be able to meet approximately 57% of our overall energy needs, significantly reducing our energy costs and making our products even more competitive".