Patent Publication Number: US-2016248230-A1

Title: Modular power plant assembly

Description:
TECHNICAL FIELD 
     The present disclosure relates to a modular power plant assembly. More specifically, the present disclosure relates to a modular power plant assembly for distributed power generation. 
     BACKGROUND 
     Generally, in remote locations and/or developing regions, such as rural areas, oil and gas installations, research stations, dam installations, and so on, utilities such as electricity may be limited or non-existent. In such regions, providing a dedicated electrical network may not be feasible and cost efficient mainly due to remoteness of such regions to the nearest power generation facility or power grid, level of demand, and/or demand inconsistency. In such situations, modular power plants are generally used to meet the limited and/or varying demand of electricity of such regions. The modular power plants are readily transportable and may be installed at any location based on the demand. 
     U.S. Pat. No. 8,816,518 describes a containerized electrical substation module. The module includes an international Organization for Standardization (ISO) 40-foot-high cube substation container. The container includes a first transformer positioned at a first end of the substation container and a second transformer positioned at a second end of the substation container. The first and second transformers are electrically connected to a number of electric generator modules. The electric generator modules are contained in separate shipping containers that are separate from and external to the substation container. The electrical substation module is configured to generate 8MVA of apparent power that is 4MVA each from the first and second transformers. 
     However, the modular power plants may include a number of modules such as a generator, a transformer, switchgear, and/or other related control systems which have to be placed on separate shipping containers for transportation. Due to the number and complexity of these modules, the modular power plants may require high transportation cost, high installation cost, high installation time, and significant installation expertise. Also, such modular power plants may not be scalable for supporting future capacity expansion. Hence, there is a need for an improved modular power plant assembly. 
     SUMMARY OF THE DISCLOSURE 
     In an aspect of the present disclosure, a modular power plant assembly for distributed power generation is provided. The power plant assembly includes a power generator assembly for generating electrical power mounted on a trailer An Alternating Current/Direct Current (AC/DC) distribution panel is electrically coupled to the power generator assembly. The AC/DC distribution panel is mounted on the power generator assembly. The power plant assembly further includes a Medium Voltage module electrically coupled to the power generator assembly. The Medium Voltage module is mounted on the trailer. The AC/DC distribution panel and the Medium Voltage module together control and distribute the electrical power generated by the power generator assembly. A plurality of auxiliary components for supplying fuel and air to the power generator assembly are mounted adjacent to the power generator assembly on a skid attached to an upper deck of the trailer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a modular power plant assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 2  is a perspective view of the modular power plant assembly provided with a housing, in accordance with an embodiment of the present disclosure; 
         FIG. 3  is a perspective view of the modular power plant assembly provided with a housing, in accordance with another embodiment of the present disclosure; and 
         FIG. 4  is a top view of the modular power plant assembly, in accordance with another embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Wherever possible, the same reference numbers will be used throughout the drawings to refer to same or like parts. Referring to  FIG. 1 , a Mobile Power Unit (MPU)  10  is shown. The MPU  10  includes various modules and subsystems arranged on a trailer  12 . The trailer  12  may have multiple axles having wheels mounted on them. For example, the trailer  12  may have four axles. The trailer  12  includes multiple supporting legs  14  for supporting the trailer  12  while parked in a stationary condition on the ground, The trailer  12  further includes a trailer floor  16  on which the various modules and subsystems are mounted. The trailer  12  may include isolating pads (not shown) mounted on the trailer floor  16 . The isolating pads may absorb the vibrations produced by the operation of various modules and subsystems mounted on the trailer floor  16 . The trailer floor  16  has a first end  18  and a second end  20 . As shown in the  FIG. 1 , a skid  22  is attached to the first end  18  of the trailer floor  16 . In the illustrated embodiment, the trailer  12  has a length dimension L 1  of approximately 60 feet and a width dimension W 1  of approximately 8 feet providing a compact footprint to minimize space requirements. The length and width dimensions L 1 , W 1  respectively of the trailer  12  may vary in accordance with the requirement and size of the various modules and subsystems to be mounted. 
     As shown in  FIG. 1 , the MPU  10  includes a power generator (PG) assembly  24 . The PG assembly  24  includes a turbine (not shown) and a generator (not shown) packaged inside a housing  26  for generating electrical energy. A reduction gearbox (not shown) is included between the gas turbine and the generator to provide variable output power. The PG assembly  24  is mounted on the trailer floor  16  positioned at the first end  18  and extending lengthwise on the trailer  12  towards the second end  20 . Isolation pads (not shown) may be attached to the bottom of the PG assembly  24  to absorb the vibrations produced due to an operation of the PG assembly  24 . The PG assembly  24  extends from the first end  18  of the trailer  12  and ends partway in between before the second end  20  of the trailer  12 . As shown in  FIG. 1 , the PG assembly  24  has a first end  28  and a second end  30 . The first end  28  of the PG assembly  24  may coincide with the first end  18  of the trailer  12 . The PG assembly  24  has a length dimension L 2  shorter than the length dimension L 1  of the trailer  12 . The PG assembly  24  may have a width dimension W 2  (not shown) matching the width dimension W 1  of the trailer  12 . The PG assembly  24  may cover whole area of the trailer floor  16  across the span of the length dimension L 2  starting from the first end  18  of the trailer  12 . The PG assembly  24  further includes various auxiliary components mounted on top of the PG assembly  24  such as, but not limited to, a turbine air inlet filter  32 , an oil mist eliminator  34 , a generator ventilation outlet  36  and an inlet air filter  38  etc. Further, an Alternating. Current/Direct Current (AC/DC) distribution panel  40  and a Medium Voltage module  42  are also electrically coupled to the PG assembly  24 . 
     The AC/DC distribution panel  40  includes multiple components inside a single cabinet  44 . The AC/DC distribution panel  40  may include components such as, but not limited to, a Motor Control Center (MCC), a Variable Frequency Drive (VFD), a Ride Through Unit (RTU), and a battery charger. All of the aforementioned components provided inside the AC/DC distribution panel  40  are pre-designed and pre-assembled inside the cabinet  44 . The components are tested before being assembled into the cabinet  44  so as to avoid any possibility of a failure while in operation The AC/DC distribution panel  40  may also include a door  46  in the cabinet  44  to access the various components for maintenance, repair or any other purposes. The AC/DC distribution panel  40  is mounted on the PG assembly  24  towards the second end  30  of the PG assembly  24 . Isolating pads (not shown) may be attached between the PG assembly  24  and the AC/DC distribution panel  40  to absorb vibrations. 
     The Medium Voltage module  42  includes multiple components such as, but not limited to, a switchgear  48 , a Neutral Ground Resistor (NGR)  50 , a battery  52 , a transformer  54  and a fire suppression unit  56 . All the aforementioned components provided inside the Medium Voltage module  42  are pre-designed and pre-assembled. The components are tested before being assembled so as to avoid any possibility of a failure while in operation. The Medium Voltage module  42  is mounted on the trailer floor  16  towards the second end  20  of the trailer  12 . The Medium Voltage module  42  includes a hollow base  58  mounted on the trailer floor  16  at the second end  20  of the trailer  12 . Isolator pads (not shown) may be attached between the base  58  and the trailer floor  16  to absorb vibrations. The battery  52  is housed in the hollow base  58 . The transformer  54  is placed adjacent to the PG assembly  24  over the base  58  and extends lengthwise towards the second end  20  of the trailer  12 , The transformer  54  is a step down transformer. The fire suppression unit  56  is placed adjacent to the PG assembly  24  parallel to the transformer  54  over the base  58  and extends towards the second end  20  of the trailer  12 . The fire suppression unit  56  may include Carbon Dioxide (CO 2 ) cylinders housed inside a cabinet  60 . The switchgear  48  is placed adjacent to the transformer  54  and the fire suppression unit  56  at the second end  20  of the trailer  12  over the base  58 . The NGR  50  is placed on top of the switchgear  48 . 
     The AC/DC distribution panel  40  and the Medium Voltage module  42  together control and distribute the power generated by the PG assembly  24  with the assistance of various aforementioned components. The AC/DC distribution panel  40  and the Medium Voltage module  42  include various electrical connections. These electrical connections include connections between various electrical components included in the AC/DC distribution panel  40  and the Medium Voltage module  42  as well as the electrical connections with the PG assembly  24 . The electrical connections are hardwired wherever possible. The electrical connections may also be plug and play connections. The plug and play connections allow flexibility of quickly engaging/disengaging various parts relative to each other. The power generated by the PG assembly  24  is distributed as per the requirement of the area where the MPU  10  is employed. 
     With continued reference to  FIG. 1 , the skid  22  attached to the first end  18  of the trailer  12  mounts multiple auxiliary components. The skid  22  mounts an exhaust silencer  62  and an exhaust stack  64 . The exhaust stack  64  allows exhaust gases from the PG assembly  24  to be released in the atmosphere. The exhaust silencer  62  helps in lowering noise emission levels for the PG assembly  24 . The skid  22  further mounts an air compressor  66 , a lubricant cooler  68 , a gas fuel filter  70 , a gas fuel meter  72 , and a liquid fuel filter  74 . The air compressor  66  is mounted in a vertical configuration, as shown in  FIG. 1 , for saving space on the skid  22 . However, in an embodiment, the air compressor  66  may also be mounted in a horizontal configuration on the skid  22 . In order to create space for horizontal mounting of the air compressor  66 , the lubricant cooler  68  may be placed on the ground surface with respect to the trailer  12 . Apart from the components mentioned, the skid  22  may mount other components as well, so as to suit the need of the required application. As opposed to other subsystems of the MPU  10  such as the PG assembly  24 , the AC/DC distribution panel  40  and the Medium Voltage module  42 , the auxiliary components may not be packaged inside a housing or a cabinet. 
       FIG. 2  shows another embodiment of the present disclosure. The MPU  10  is provided with a housing  76  on the top of the PG assembly  24  so that the various auxiliary components mounted on the top of the PG assembly  24  are covered within the housing  76 . The housing  76  may be a rectangular housing of the same type as the housing  26  of the PG assembly  24 . The housing  76  also includes pre-defined space for the auxiliary components mounted on the skid  22  except for the exhaust silencer  62  and the stack  64 . 
       FIG. 3  illustrates another embodiment of the MPU  10 . The exhaust silencer  62  and the exhaust stack  64  are integrated with the PG assembly  24 . The exhaust silencer  62  and the exhaust stack  62  are placed on the trailer  12 . The gas fuel filter  70  and the gas fuel meter  72  are also placed on the trailer  12  adjacent to the exhaust silencer  62  and the exhaust stack  64 . Other auxiliary components may be placed on the skid  22 . Alternatively, the other auxiliary components may be placed inside the housing  76 . 
       FIG. 4  shows another embodiment of the present disclosure. A flat container  78  is used to arrange the various subsystems and modules. In an embodiment of the present disclosure, the flat container  78  is a designated International Organization for Standardization (ISO) flat container. The flat container  78  may have a length dimension L 3  of approximately 40 feet. The PG assembly  24  is placed on the flat container  78 . The PG  24  assembly may be connected to the flat container  78  with spring isolators or a mechanical connection. The flat container  78  has a first end  80  and a second end  82 . The AC/DC distribution panel  40  is mounted on the PG assembly  24  towards the second end  82 . The exhaust silencer  62  and the exhaust stack  64  are placed on the flat container  78  towards the first end  80  of the flat container  78 . The exhaust silencer  62  and the exhaust stack  64  may be integrated with the PG assembly  24 . The gas fuel filter  70  and the gas fuel meter  72  are also placed on the flat container  78 . The gas fuel filter  70  and the gas fuel meter  72  may be placed adjacent to the exhaust silencer  62  and the exhaust stack  64  on the flat container  78 . A first submodule  84  is attached to the flat container  78  at the first end  80  of the flat container  78 . The first submodule  84  may be connected to the flat container  78  via a mechanical connection, The mechanical connection may be of any type including, but not limited to, a fastener, welding etc. The first submodule  84  mounts multiple auxiliary components. The auxiliary components include the air compressor  66 , the lubricant cooler  68 , and the liquid fuel filter  74 . The first submodule  84  may also mount any other auxiliary component if required, according to the need of the application. In an embodiment, the first submodule  84  may have a length dimension L 4  of 20 feet. A second submodule  86  is attached to the flat container  78  at the second end  82  of the flat container  78 . 
     The second submodule  86  may be connected to the flat container  78  via a mechanical connection similar to the connection between the first submodule  84  and the flat container  78 . The second submodule  86  mounts the Medium Voltage module  42 . The Medium Voltage module  42  includes the switchgear  48 , the NGR  50 , the battery  52 , the transformer  54  and the fire suppression unit  56 . These subsystems are arranged in the same manner relative to one another as arranged on the MPU  10 . The components placed on the second submodule  86  may be electrically connected to the PG assembly  24  placed on the fiat container  78  via plug and play connections. In an embodiment, the second submodule  86  may have a length dimension L 5  of 20 feet. 
     The arrangement of various subsystems and modules arranged on a combination of the flat container  78  and the first and second submodules  84 ,  86  is called as a Modular Power Plant (MPP)  88 . The MPP  88  offers ease of transportation and portability. The Out container  78  may be transported on any standard trailer or ISO Container Shipping Vessel etc. The first and second submodules  84 ,  86  may be separately transported than the flat container  78 . After reaching the place of operation of the MPP  88 , the first and second submodules  84 ,  86  may be readily attached to the flat container  78 . 
     INDUSTRIAL APPLICABILITY 
     Power generation plants are generally centralized and require electricity to be transmitted over long distances. However, there may still be locations that are classified as remote and it may not be possible to transmit the electricity generated by the conventional means to such locations. Distributed power generation methods are used to cater to power requirements of such locations. Distributed power generation refers to producing electricity near the end users by employing small scale technologies in an efficient and comparatively less expensive manner. Various methods are used for distributed power generation such as, but not limited to, solar power, wind power, hydropower, energy produced from waste-products etc. Another such method is to provide an easily transportable and readily installable MPU  10 . 
     The MPU  10  provides a portable and readily transportable means of distributed power generation. The MPU  10  includes the PG assembly  24 , the AC/DC distribution panel  40 . the Medium Voltage module  42  and various other auxiliary components arranged on the trailer  12 . The trailer  12  provides for flexibility in transportation of the MPU  10 . The trailer  12  needs to be attached on a self-propelled vehicle such as a truck etc. and may be easily transported to the required location. The trailer  12  also provides mobility of the MPU  10  at a worksite. Further, the use of the spring isolators between the trailer  12  and the PG assembly  24  allows the MPU  10  to be installed on a wide variety of foundation types without being impacted by vibration of the foundation. 
     The MPU  10  also offers easy installation procedures. The MPU  10  includes various modules and subsystems which are pre-designed and pre-tested. Further, these modules include hardwired electrical connections wherever possible and provide for plug &amp; play connections means. These types of packaging and connections make it easier to install the MPU  10  at the worksite. Generally, it may take less than a day to install the MPU  10  at the worksite in a configuration which is ready to produce the required power. The MPU  10  is a standalone and independent distributed power generation solution. The MPU  10  may not require any external support or attachment to the grid to generate power. 
     While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.