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Successful manufacturing and installation of Kaishan’s first modular power station

Successful manufacturing and installation of Kaishan’s first modular power station

2017/06/13 publish by Kaishan compressor

The successful completion of installation of the first unit for Jiangsu Chenggao power generation project on May 21 marks the success of Kaishan’s first ORC power generation station designed, manufactured and installed based on modularity

Jiangsu Chenggao is a manufacturer of new types of engineering plastics. Kaishan’s power generation unit is able to substitute the company’s condenser involved in its production process. The benefit of the use of our power unit include not having to run the condenser, the operation of which incurs expenses, and the economic benefits created by electricity generated. A EPC project by Kaishan, this unit is China’s first large unit designed, manufactured and installed based on modularity and anmodular esterification steam power unit in China, with 1.8MW in installed capacity.

Conventional power station construction involves foundation digging, laying equipment foundation, process pipeline fitting and welding, installation of valves and electrical instruments, and so on. The problem with construction of conventional power station is long period of construction, poor site working conditions, construction quality difficult to control, difficulty in moving equipment, large area needed for construction, to name just a few. Compared with conventional way of construction, modular power generation station construction has many advantages, such as only 100 square meters occupied owing to modular integration, easier site installation so that construction period is effectively reduced.


This unit comprises two layers. Layer one comprises 4 modules, namely power, oil separation, heat exchange, pump set, and electrical control cabinet modules. Layer two has only a condensing module. After being shipped to site, layer one can be conveniently assembled with bolts, much like blocks building. Owing to the convenience of installation, the installation time for layer one equipment has been shorted from 10-15 days to 3-5 days. If installed on site where the construction condition is usually dirty, the screw expander power generation station can easily get extraneous dirty matter and rusts into its internal spaces. Modular manufacture whereby pipes and fittings are pre-manufactured and assembled at factory workshops avoid the above cleanness problem. Moreover, the reduced amount of site welding reduces site flame and in turn eliminates safety hazards. The establishment of standardized design database characterized by simulation, and the use of factory fully automated assembly line brings in a one-time acceptance rate of 99% and improves product quality. In addition, construction cost is reduced by a huge amount.

Modular and integrated design places high demand on design personnel because they are required to be more considerate and to optimize the layout of various components of the unit. The aspects of modular spaces considered by designers include stress, pipeline direction, integration, and subsequent maintenance and services, which put higher demand on designers. Modular design also means greater difficulty for manufacturing. For instance, modular assembly of the unit requires accurate blanking, precise fitting and assembling, all-position welding, determining assembling sequence, etc. To ensure the success of modular manufacturing, Kaishan Energy, a subsidiary of Kaishan Group, adopted special processes and preventative measures.

The advantages of modular power station will appear more and more as Kaishan screw expander power projects are promoted progressively. There is reason to believe modular power stations will supersede stations conventionally constructed, because they are better in terms of competitiveness and economic benefits. The success of this project lays the foundation for the development of projects to be constructed in the US and Indonesia. We are certain Kaishan modular ORC power stations have great prospects and will enjoy a bright future! 
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