DST Systems, Inc. – Generator Plant Evaluation & Upgrade
Apr 24, 2013

DST Systems, Inc.

Generator Plant Evaluation & Upgrade

For this project, we first completed a detailed engineering evaluation to determine upgrades and modifications that could be made to the 5,000 kW engine generator plant to improve performance and efficiency.

Our engineering analysis included system testing each of the five generators independently and as a system (with all engines operating). From testing, we found that the engine radiator systems were not operating at design. Upon further analysis and testing, we determined that the fans serving the radiators were simply not capable of providing the airflow needed to remove the engine heat at full load. In conclusion, our engineering evaluation recommended replacing the radiators with new units designed to meet the specifications for the generator and engine.

Other proposed upgrades included adding monitoring devices so we could monitor entering and leaving radiator water temperatures. This was done so we could validate operation and monitor radiators for deterioration. From generator inspection and testing, we recommended rear seal replacement.

For the project implementation, we provided design and construction management services for the entire upgrade. This included developing and maintaining a detailed construction schedule clearly showing the responsibilities of all trades. As part of the project design criteria, the 5,000 kW generator capacity had to be maintained during the construction process. To accomplish this requirement, we provided a temporary 1,500 kW stand-by generator. The stand-by unit was temporarily wired into the chiller plant alternate power feed. This allowed us to remove approximately 1,000 kW demand off the main generator plant, which enabled us to have one generator off-line at the time during the project implementation.

The entire plant upgrade was completed in 14 days from the start of construction. Project start-up included re-commissioning all alarms, including monitoring controls, automatic transfer schemes, and fuel supply systems.