RGA Engineering y Projects

  • Client:  Polar Commercial Foods
  • Inverted H/H:  1180
  • Location:  Mariguitar, Venezuela.

Alimentos Polar Comercial asked RGA to carry out a level II electrical audit at the Canned Plant (Marigüitar, Sucre state, Venezuela), in order to determine the main potential for energy savings present in the facility, in order to positively influence the indicators of electricity consumption carried by the corporation. The activities carried out were the following:

  1. Development of APC load census – Marigüitar Plant.
  2. Determination by means of the Pareto principle of the most important loads, location and type of service.
  3. Visual inspection and data collection of the electrical installations (boards, protections and equipment) of the Production and Services Areas: Refrigerated Cellar, White Water Treatment Plant (PTAB) and the Residual Water Treatment Plant (PTAR); as well as the so-called Perimeter Areas.
  4. Record of load for seven continuous days using the FLUKE brand equipment , model PowerLogger 1735  in: Main Substation, Service Substation, Refrigerator and PTAB.
  5. Development of single-line electrical diagram of APC-Marigüitar Plant.

Results obtained

  • It was determined that the refrigeration system of the Cellars was the cause of the increase in the indicator due to lack of regulation under partial operation .
  • Development of energy saving proposals by plant area and energy use. Approximate estimate of global savings achievable 30%.
  • Survey of non-conformity points for annual investment plan .
  • Client:  Central El Palmar, SA
  • Inverted H/H:  2575*
  • Location:  San Mateo, Venezuela.

RGA developed the project for the coordination of electrical protections and short circuit levels at Central El Palmar, a sugar mill with an Installed Capacity of 30 MVA , operating under an IPP scheme (of 10 MW of generation capacity between steam and gas turbines), in order to determine the necessary infrastructure improvements for a correct performance of the electrical distribution system, thus reducing unscheduled plant shutdowns and the loss of profit caused by them.

The activities developed were the following:

  1. Facility load census.
  2. Inspection of the different electrical equipment and substations, cabinets, CCM and boards to determine the degree of compliance with the National Electrical Code (CEN) and NFPA.
  3. Lifting of protections.
  4. Update of the one-line diagrams.
  5. Proposal for general improvements.
  6. Carrying out pre-coordination of protections and definition of those “Not coordinable”.
  7. ETAP simulation for load flow, short circuit levels and protection coordination.

*Due to country situation issues, the project was suspended until the load flow of the installation was completed.

  • Client:  GCP Technologies Venezuela, SA
  • Inverted H/H:  430
  • Location:  Valencia, Venezuela.

RGA was required to carry out an Energy Audit of GCP Tecnologías Venezuela SA, a subsidiary of GCP Applied Technologies in the country, in order to develop a structured and specialized energy saving plan, based on the foundations of the law but feasible over time. .

Based on RGA’s expertise in the matter, an advanced level I audit was proposed in accordance with the provisions of the ISO 50002:2014 standard , limiting its scope to the electricity consumption of the plant. Among the activities carried out are:

  1. Cargo census survey.
  2. Estimation of the energy consumption of the installation based on the information provided by the Processes department, considering the load factors and typical efficiencies of the IEC 60034-1 standard.
  3. Determination of focal points of energy interest, according to power and consumption, by plant area and type of energy use.
  4. Record of load for seven continuous days using the FLUKE brand equipment, model PowerLogger 1735, on the main low voltage board of Construction.
  5. Review of the level of compliance with government regulations and billing for 24 months.
  6. Development of energy indicators, baseline and plant energy saving potential.

Results obtained

  • Approach of short-term saving measures, for 27% of current consumption , in motors, air compression, and lighting .
  • Maximum global savings achievable estimated  57% .
  • Approach of cost-effective alternatives to LED luminaires for lighting control, especially during non-working days. Approximate savings 80% .
  • Client:  GCP Applied Technologies
  • Inverted H/H:  240
  • Location:  Valencia, Venezuela.
RGA carried out the electrical installation in explosive areas for the placement of an emergency start and stop station that would serve the aluminized tank of the Lacas Plant. The purpose of the service was to remotely carry out, as close as possible to the agitator, the start of the operation so that the operator would not have to separate himself visually from the process during start-up. An electrical installation in explosive areas (classified areas) depends on the type of flammable product handled in it, which can range from vapors to dust and particles. In this case, it was a division 1 type area (flammable organic vapors), for which it is required that all devices and accessories be of the explosion proof  type and that heavy series rigid pipe be used. In turn, in accordance with local and international regulations, fire seals must be placed near the spark generation points, as well as at the exit of the classified space, these being filled with chicco cotton and cement. It should be noted that the sealing must be done last because once the cement is placed, modifications to the system can no longer be made. Specifically, the work consisted of the following activities:
  • Placement of start/stop station and emergency stop.
  • Installation of heavy series rigid conduit pipe, with explosion proof accessories and fire seals.
  • Intermediate pipe installation (IMC) for outdoor areas, using an existing pipe rack at a height of 6 meters.
  • Wiring and connection in frequency inverter.
  • Frequency inverter programming and commissioning.
  • Client:  Polifilm de Venezuela, SA
  • Inverted H/H:  840
  • Location:  La Victoria, Venezuela.
RGA developed and executed the entire LED lighting system and power outlets for the expansion of the Polifilm de Venezuela transparent PVC sheet production line, in a record period of 7 days to meet the customer’s production requirements. This area, ready to operate 24/7, has illuminance levels that exceed what is established by the Venezuelan regulation COVENIN 2249-93. Unlike the standard in lighting installations in Venezuela, all the technology used in the execution consisted of LED luminaires, both in hoods (ambient lighting) and 2×18 W lamps with anti-dust screen, for work stations. The following activities were carried out:
  • Installation of conduits and wiring for the lighting system and outlets.
  • Installation of 8 bell-type LED luminaires at a height of 10 meters.
  • Installation of 25 lamps with an anti-dust screen, for night lighting on platforms and work stations.
  • Manufacture of supports on site to meet the specific requirements of the area.
  • Adaptation of the connection for the expansions of the air conditioning system that would serve the capsule of the packing area.
  • Location of transformer, main board and lighting.
  • Client:  Central El Palmar, SA
  • Inverted H/H:  725*
  • Location:  San Mateo, Venezuela

With the intention of improving the energy performance of the plant and bringing it up to international standards, RGA was required to carry out an energy audit of CEPSA (level II), a sugar mill with 30 MVA installed capacity and 10 MW self-generation, applying the ISO 50002:2014 standard both at the level of processes and consumption of electricity and fossil fuels.

Among the activities carried out in the energy audit of CEPSA are:

  1. Based on the load census of the plant, raised for the project of coordination of protections ( see more ) to develop the pareto of consumption.
  2. Recognition of the sugar manufacturing process.
  3. Define process bottlenecks.
  4. Establishment of load monitoring points for the most important substations.
  5. Development of mass and energy balances
  6. Define points for the reuse of residual heat.

Results obtained

  • Proposal for the incorporation of a back pressure steam turbine. Efficiency increase approximately 23% .
  • Estimated process water leaks approximately 30% .
  • Proposal for replacement of techniques for cleaning areas with hot water.

*Due to country situation issues, the project was suspended until the load flow of the installation was completed.

This is a staging enviroment