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Fuchuang successfully delivered a 10.5kV/3MW high-voltage generator set paralleling and grid connection project in Mongolia

I. Project Background: Power Upgrade Needs Under Extreme Climate Conditions

A Mongolian industrial enterprise, due to the expansion of its production scale, needed to add a 3MW high-voltage generator set system to improve power supply reliability and achieve flexible grid connection with the existing municipal power supply.

This project faces two core challenges:

**Extreme Climate Challenges:** Mongolia has a continental climate with significant diurnal temperature variations. Winter temperatures can reach as low as -40°C, while summer temperatures can soar to 35°C. Electrical equipment must withstand these dramatic temperature changes and low-temperature startup.

**Equipment Compatibility Retrofitting:** The client requires utilizing the existing high-voltage switchgear foundation. New equipment must be precisely matched to the existing installation locations and interfaces to avoid increased costs and project delays due to large-scale modifications.

II. Core Requirements: Precise Matching and Functional Implementation

Based on the project site conditions and customer requirements, four core requirements are identified:

Equipment Customization: Three new generator control boxes (compatible with existing installation dimensions), one grid-connected control box, and one KYN28A-12 grid-connected cabinet are required to ensure seamless integration with the existing high-voltage switchgear system;

Extreme Environment Adaptability: All equipment must meet the wide temperature range requirement of -40℃ to 35℃, and also possess sand and dust resistance and low-temperature condensation resistance;

Parallel Operation and Grid Connection Functionality: Achieve stable parallel operation of the 3MW generator set, and be able to safely switch and connect to the original mains power system, ensuring power supply continuity;

**Precise On-Site Implementation:** It is necessary to confirm the on-site installation location, cabinet dimensions, and existing system parameters in advance to ensure the feasibility of the solution and smooth equipment installation.

III. Fuchuang Solution: Customized System Design and Climate Adaptation Technology

Based on project requirements, the Fuchuang team developed a customized solution from three dimensions: compatibility, weather resistance, and functionality.

**Precise Equipment Size Customization:**

Technical engineers were dispatched to Mongolia for on-site surveying to accurately measure the existing high-voltage switchgear installation space, interface specifications, and wiring layout, ensuring direct adaptation to the existing installation location without altering the civil engineering structure.

The KYN28A-12 grid-connected cabinet adopts a modular design, optimizing the internal component layout to meet the 10.5kV high-voltage insulation standard while matching the existing cabinet's installation spacing and cable interfaces.

Extreme Climate Protection Upgrade

Low Temperature Adaptability: The unit control box and grid-connected control box are equipped with a low-temperature heating module (automatic start at -40℃), a low-power insulation layer, and low-temperature resistant components (operating temperature -55℃~85℃) to ensure normal start-up and operation of the equipment in low-temperature environments during winter;

High Temperature and Dustproof Design: The cabinet adopts an IP54 protection rating and is equipped with an intelligent cooling fan (automatic start at 30℃) and a dust filter to avoid equipment failure caused by high temperature overload and sand and dust intrusion in summer;

Temperature Change Adaptability: The cabinet material and sealing structure are optimized to reduce the impact of drastic temperature changes on insulation performance, complying with the IEC 62271-202 high-voltage equipment environmental adaptability standard.

Parallel Grid Connection System Optimization

Parallel Control Logic: The generator control box integrates a PLC intelligent control module to achieve balanced load distribution and synchronous parallel operation of the three generator sets, with a response time ≤0.3 seconds, avoiding inrush current during parallel operation;

Grid Connection Protection Function: The KYN28A-12 grid connection cabinet is equipped with a microcomputer-based integrated protection device, supporting multiple protections including overvoltage, undervoltage, overcurrent, and frequency anomalies. It also integrates anti-islanding protection to ensure grid safety when connected to the mains power supply;

System Linkage Design: The grid connection control box acts as the core hub, achieving three-way signal linkage between the generator set, the existing high-voltage cabinet, and the mains power supply. It supports both manual and automatic switching modes to meet the power supply needs of customers under different operating conditions.

IV. Implementation Process: Full-Process Control from Professional Survey to Successful Delivery

On-site Survey and Solution Confirmation: The technical team conducted a 3-day on-site survey in Mongolia, recording environmental parameters, existing equipment models and installation dimensions, and outputting detailed system solution diagrams (including electrical schematics and cabinet dimension diagrams). Production commenced after confirmation with the client.

Factory Prefabrication and Simulation Testing: After completing equipment production according to the solution, 72 tests were conducted in the Fuchuang Laboratory to simulate the extreme climate of Mongolia (-40℃ low-temperature chamber, 35℃ high-temperature chamber). Hourly full-load testing verified equipment operational stability; simultaneously, a simulated grid-connected system was built to test paralleling accuracy and grid protection functions, ensuring compliance with standards.

**On-site Installation and Commissioning:** A specialized construction team was dispatched to Mongolia to efficiently complete the installation and wiring of 3 unit control boxes, 1 grid-connected control box, and the KYN28A-12 grid-connected cabinet; during the commissioning phase, five simulated power outages and unit paralleling scenarios were conducted to verify that the system switching response time was ≤0.5 seconds, and all parameters met design requirements.

**Acceptance and Delivery:** The project was completed within the agreed timeframe. After joint acceptance by the customer and local power regulatory authorities, the equipment's insulation performance, paralleling accuracy, and adaptability to extreme environments all met standards, and the equipment was officially put into operation.

V. Project Achievements: Stable Operation Gains Customer Recognition

Stable Operation in Extreme Environments: After the project was put into operation, it withstood the tests of Mongolia's winter temperatures of -38℃ and summer temperatures of 32℃. All equipment operated stably without any malfunctions caused by temperature changes, ensuring continuous production for the company;

Highly Efficient and Reliable Parallel Grid Connection: The 3MW generator set can achieve rapid parallel operation and smooth switching with the mains power grid. It has successfully handled four mains power fluctuations without causing production interruptions, improving power supply reliability to 99.8%;

Customer Testimonials: "The Fuchuang team precisely solved our problems of equipment compatibility and extreme climate adaptation. The solution was professional, the implementation was efficient, and the equipment has been operating stably since its commissioning, providing a solid power guarantee for our production." — Company Engineering and Technical Director

VI. Case Summary

This project in Mongolia fully demonstrated FOCAC's technical strength and service capabilities in the fields of "equipment retrofitting + extreme climate adaptation". Addressing the client's existing equipment compatibility needs, FOCAC achieved seamless integration of the old and new systems through precise on-site surveys and customized design. Facing extreme climates ranging from -40℃ to 35℃, targeted protection technology upgrades ensured stable equipment operation. In the future, FOCAC will continue to deepen its expertise in overseas projects with special operating conditions, providing more tailored high-voltage power solutions to global clients.