Backup power plant at Roanne Hospital, France
Intervention type
Pre-study, audit, study, commissioningCustomer
Roanne HospitalDate of completion
Location
Roanne, FranceAbout installation
1. Installation context
The Roanne Hospital recently undertook a complete modernization of its backup power plant . The aim was to guarantee a reliable, secure and uninterrupted power supply. This is essential for the smooth running of critical services. Indeed, in a hospital environment, power supply stability is essential. Even a brief power cut can have serious consequences. This affects continuity of care, patient safety and sensitive medical equipment.
In this context, Positif-Veolia the project's prime contractor, called on the expertise of CRE Technology for the automation and control-command aspects. Our mission was to carry out a complete retrofit, including replacement of obsolete equipment and validation of the various operating modes. In addition, a centralized, scalable supervision system was installed to facilitate plant management. The main objective was to improve redundancy of power supply in the event of a main network failure. In addition, coordination between gensets was optimized to enhance system reliability. Finally, the solution implemented simplifies the day-to-day work of the technical teams on site.
2. Issues encountered by the customer
On the one hand, one of the critical points at the outset of the project was the obsolescence of the control cards used until then. The plant was still equipped with CRE UNIGEN+ cards, which no longer met current performance and safety standards.
In addition, the system exhibited unsatisfactory dynamic behavior, mainly due to the inappropriate use of HEINZMANN KG 16 speed controllers, which affected both stability and optimization of the power plant's operation.
The absence of effective regulation posed risks in the event of grid failure, with insufficient coordination between the gensets.
3. Project challenges
The aim of the project was to guarantee total power continuity for the critical infrastructures of the Roanne hospital. It also involved optimizing gensets management. To achieve this, load ramp-up had to be gradual, power distribution balanced, and energy efficiency improved.
In addition, the installation of a modern supervision system was a key point. It had to enable the technical teams to monitor the plant's status in real time. This also facilitated maintenance and enabled faults to be anticipated.
The solution we provided
To meet these objectives, CRE Technology deployed a complete, tailor-made solution, adapted to the site's technical constraints and reliability requirements.
The power plant comprises four generators. Two are 1600 kVA and two are 2000 kVA. The generators are interconnected in a high-voltage loop. This guarantees total redundancy of power supply. Our synchronizing modules enable automatic synchronization between the gensets and with the grid. In the event of a power failure, load ramp-up is rapid, smooth and balanced.
The heart of the system is i4GEN's centralized supervision system, which displays all plant parameters in real time and allows consultation of the eventhistory . This intuitive interface greatly facilitates day-to-day operation and preventive maintenance.
CRE Technology provided the control and monitoring solutions for this project, guaranteeing perfect compatibility between all components.
1. GENSYS COMPACT PRIME module – Genset management
Four modules GENSYS COMPACT PRIME modules have been installed (one for each genset), enabling autonomous and coordinated management of the generators :
- Automated motor start-up and shutdown: each GENSYS automatically controls unit start-up as soon as a grid failure is detected, guaranteeing rapid load ramp-up.
- Genset protection: Includes the electrical and mechanical protection required for genset safety, in line with current hospital standards.
- Parameter monitoring and display: Allows simple visualization and control of mechanical and electrical parameters.
- Synchronization capability: Automatic synchronization of the 4 groups with each other and with the main power grid, ensuring seamless transition back to the grid.
- Load sharing (kW/kVAr): Includes charge and discharge ramp management for optimized energy distribution.
- Dynamic genset management: Automatically activate or deactivate generators according to actual plant load, to optimize overall power plant operation.
2. MASTER COMPACT 1B module – Coordination of gensets with the grid
One module Master Compact 1B has been installed to ensure complete coordination of the power plant :
- Automated power plant start & stop: Global orchestration of start-up, shutdown and load transfer sequences for all units.
- Paralleling protections: Integrates paralleling protections with the grid and ensures conformity of voltage, frequency and phase parameters before synchronization.
- Parameter monitoring and display: Centralized supervision of key data, with display of kW/kVAr load ramps for each process phase.
- Synchronization capability (No break change over): Enables a seamless return to the grid thanks to controlled paralleling no break change over between the power plant and the EDF grid.
- Load sharing (kW/kVAr) & ramps between different sources: Manages load/discharge ramps between gensets and the grid to ensure smooth, jolt-free transfers.
3. BTB COMPACT module – BTB circuit-breaker management
The three BTB Compact modules are dedicated to the management of cross-connector circuit breakers in a loop architecture:
- Automatic opening/closing of the tie breaker: In AUTO mode, sequences are managed automatically by the module. A MAN mode is available for manual control of the circuit-breaker using the buttons on the front face.
- Parameter monitoring and display: Supervision of synchronization before circuit-breaker closing (voltage, phase, frequency), via integrated Synchroscope.
- Synchronization capability: Automatic synchronization between two electrical sources prior to paralleling, ensuring impact-free transition.
- Load sharing/equalization (kW/kVAr): Once synchronization has taken place, the BTB applies an equalization ramp until the two parts of the grid are fully balanced.
4. I4GEN module – Power plant supervision
Five i4Gen installed: one per generator and one for the common area (via Master Compact 1B):
- Automatic display of the plant's single-line diagram: Allows technical teams to view power plant status and equipment status in real time.
- Time-stamped eventlog : Local history alarms, faults and events to facilitate post-incident analysis and preventive maintenance.
- Automatic time synchronization over the grid: Applied to all controllers to ensure data consistency.
- Detailed notifications by email: Automatic alerts in the event of an alarm or fault.
Conclusion
Thanks to CRE Technology, the Centre Hospitalier de Roanne now has a reliable, high-performance emergencypower plant . Moreover, the plant is designed to be simple to operate, while meeting the stringent requirements of the hospital sector.
The power plant 's operation is now fully automated, from unit start-up to load balancing. In addition, the i4GEN supervision system provides smooth control with real-time alerts and secure remote access.
In addition, the installation is scalable, ensuring compatibility with future extensions or renewable energy sources. This project illustrates CRE Technology's ability to modernize sensitive sites with robust, integrated solutions. Last but not least, it confirms our expertise in supporting critical facilities in their transition to safe, sustainable power systems.
Related products
GENSYS COMPACT PRIME
The GENSYS COMPACT PRIME is designed for advanced management of multiple generators in power plants, while offering interoperability with other types of energy sources for more complex systems.
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MASTER COMPACT 1B
The MASTER COMPACT 1B is designed to manage a mains incomer with a single circuit breaker. It allows advanced interoperability with various energy sources, such as generators, inverters or other mains incomers.
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BTB COMPACT
The BTB COMPACT is designed to manage a tie-breaker, which is essential for segmenting a facility's busbar into multiple separable busbars, while ensuring precise synchronization between the different sources.
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