MCA, logo, automation, motor, voltage, industrial, containers, electrical
MCA, logo, automation, motor, voltage, industrial, containers, electrical, projects
PDS, Power Distribution, Systems, Tekpan, logo, dark
MCA, logo, automation, motor, voltage, industrial, containers, electrical, projects

Technical Overview

Our Focus

CHOOSING THE RIGHT MOBILE SUBSTATION FOR THE PROJECT

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With the increasing demand for modular plants and removable mining equipment, Boksburg based MCA Projects, part of the MCA Group, has seen a rising demand for modular substations and removable modular substations. MCA projects looks at the pros and cons of the various mobile substation options.

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Mobile substations can be categorized or identified in three different ways – there is the basic standard containerised substation, the E-House and the Modular substation. The containerised substation is the most popular, typically consisting of standard 12m or 6m shipping container “once used” (term used to describe a containers condition) a secondhand container or brand new one will be customized into electrical substations to suit the specific customer requirements.

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Containerised Substations generally maintain the structural framework of the original container, with modifications to mainly to the floor, wall, ceiling, and doors. With minimal steel fabrication required and the convenient sizing of this container option, the containerised substation is by far the most cost effective as it requires the least labor-intensive modification and is particularly easy to transport in comparison with the E-House or a modular substation.

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E-House (“Electric House”) is typically a fully custom-built, a prefabricated structure that is designed to suit specific applications and house whatever equipment is required. E-Houses come in various shapes and sizes and can vary depending on the required application. Some look like normal prefabricated buildings while others form part of mobile cranes, for example on a stacker or a reclaimer.

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Modular Solution is a much larger substation that consists of two or more substation sections or E-House sections which are joined together to create a larger substation. These are ultimately used where the time constraints are a major factor or where the conditions on site are too extreme for civil works. These units are typically constructed in a convenient location, tested and cold commissioned, broken up into multiple sections and then reassembled on site.  A typical example of a modular substation could be a 12m and 6m container that are placed in line with interleading doors, or two containers of the same size fully equipped with a bus-trunking joining the busbars of two sections of an MV or LV Board

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Fully type tested equipment which is in accordance with the latest SANS/IEC standard. In addition, the installation must be carried out with in the guidance provided in OEM manuals.

Containerised Substations

Scale concept to completed project

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Scale concept to completed project

MARINE CONTAINERS

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Safety is always the most important factor to consider when it comes to the design and selection of the mobile substation, as it is an area of fatal risk if the engineering and design if safety factors are not addressed adequately. Fire risks are reduced by removing the standard wooden floor fitted to containers and replacing with a metal clad flooring. Small electrical faults generate massive amount of heat which make the wooden flooring a fire hazard, compromising the entire operation and capital investment.

Coating system

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The container is made from a steel type called Corten Steel which is also known as weathering or self-healing steel for corrosive type conditions. In our proposed use of containers for the LV substations the steel type used for these is a more resistant type steel to weather corrosive conditions. We also follow a strict paint procedure on all types of substations that we manufacture (containerised and custom E-houses) which can be found in the attachment for reference and any discussion points.

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Our proposed coating system for the external coating of a container is up to C5-M environment. This is the highest rating that can be offered. This is in line and in accordance with ISO12944-5. This coating system has a 20yrs+ corrosion resistance certification if the correct care and maintenance regiment is followed.

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RECOMMENDED SURFACE PREPARATION Remove all oil, grease, and soluble salts by washing all areas with Carbo clean 250 and rinsing with water. Dry abrasive blast to near white metal ins accordance with Sa2 ½ of the International Standard ISO 8501-1:1988 to abstain a surface profile of 40 to 80 microns.

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TOP SECTION AND SIDE OF CONTAINER Our proposed coating system for the external coating of a container is up to C5-M environment. This is the highest rating that can be offered. This is in line and in accordance with ISO12944-5. This coating system has a 20yrs+ corrosion resistance certification if the correct care and maintenance regiment is followed.

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FLOOR SECTION AND UNDERSIDE OF CONTAINER Our proposed coating system for the external coating of a container is up to C5-M environment. This is the highest rating that can be offered. This is in line and in accordance with ISO12944-5. This coating system has a 20yrs+ corrosion resistance certification if the correct care and maintenance regiment is followed.

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NB – if the correct care and maintenance program is followed by the end user the lifespan of a containerised substation and an E-House can be 30+ years. Quarterly inspection for corrosion light sanding and paint touchup is all that is required to prolong the lifespan of this solution well beyond 30 years.

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NEW 2022 HURRICANE 15M TRUCK SPRAY BOOTH – BACK EXTRACTION

Spray booth with CE certification ; Light strength. ≥1000 Lux. ; Certification. CE, ISO:9001

Our proposed coating system for the external coating of a container is up to C5-M environment.  This is the highest rating that can be offered. This is in line and in accordance with ISO129445-5

LNG MOZAMBIQUE 2020
ISO12944-5. This Coating system Has a 20 Yrs+ Corrosion Resistance Certification

INTERNAL FISHING

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RECOMMENDED SURFACE PREPARATION Remove all oil, grease, and soluble salts by washing all areas with Carbo clean 250 and rinsing with water. Dry abrasive blast to near white metal ins accordance with Sa2 ½ of the International Standard ISO 8501-1:1988 to abstain a surface profile of 40 to 80 microns.

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TOP SECTION AND SIDE OF CONTAINER Our proposed coating system for the external coating of a container is up to C5-M environment. This is the highest rating that can be offered. This is in line and in accordance with ISO12944-5. This coating system has a 20yrs+ corrosion resistance certification if the correct care and maintenance regiment is followed.

INTERNAL FISHING

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6m generator container – soundproof generator container

Outlet attenuator 400kva 

Outlet attenuator 20kva 

Generator genset control panel and distribution (75kw dol – dummy load 400kva, 10kw dol – dummy load 20kva)

Commissioning and software set up 

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Hipertec® Wall Sound is a sandwich panel with an insulation core of mineral wool and steel cover sheets, the internal sheet being perforated.  This panel is perfectly apt for buildings with high requirements on sound insulation and sound absorption. The design of the internal sheet improves room acoustics substantially. This system (patented by Metecno)

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Reaction to fire

Building material classified as A2-s1, d0 non-combustible according DIN EN 13501-1; mineral wool core A1, non-combustible, melting point < 1000°C 

Thermal conductivity

λ=0,044 W/m.K under the terms of DIN 4108 and DIN EN 13165
The insulation values are regularly monitored by external bodies and may be applied without any further reduction.

FIRE PROTECTION

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Fire risks are reduced by removing the standard wooden floor fitted to containers and replacing with a metal clad flooring. Small electrical faults generate massive amount of heat which make the wooden flooring a fire hazard, compromising the entire operation and capital investment. Simple fire detection systems should be installed to detect smoke in the substation. Air conditioners and HAVAC systems should be shut down in the event of a fire as they fuel the fire.

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Arc flash and high fault current should be considered an extreme risk. Arc flask is a hot topic in the industry and has recently been added to the Mine Health and Safety Act in South Africa. The act calls for the employer to consider the risk and heat energy that is emitted by an Arc flash and the danger there from. With that being said, “What happens when thing go bang?” it is critical that the engineering team and mobile substation manufacturer have the precaution in place to this important question. Fully type tested equipment which is in accordance with the latest SANS/IEC standard. In addition, the installation must be carried out with in the guidance provided in OEM manuals.

CONTAINERISED SUBSTATIONS PLUG AND PLAY SOLUTIONS

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Cost saving, reduces on site set up and  relocation expenses

Comprehensive MV and LV portfolio of power options

Containerised substation solutions for both MV and LV applications

Containerised substation – excellent for extreme environments and specific  client requirements

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Customised mini substations

Manufactured to specifications and according to region & environmental requirements

Excellent for extreme environments and specific client requirements

Fitted LV/MV switchgear, PLC, VSD’s, RMU’s, Transformers, Generators and Fire protection    

Portable power solutions, robust, plug and play, ready to use

CONTAINERISED SUBSTATIONS PLUG AND PLAY SOLUTIONS

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E – House – enhances installation time thanks to plug and play

E – House – cost saving, reduces set up and relocation expenses

E – House  – comprehensive MV and LV portfolio of power options

Fully customised E-house solutions designed to clients’ requirements

RENEWABLE ENERGY AND OVERHEAD LINE INSTALLATION

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Mobile outdoor skids for both MV and LV  applications

Ski mounted solutions do not require any plinths or slab preparation

Excellent for extreme environments

Skids can be fitted LV/MV  switchgear, PLC, VSD’s, RMU’s,  Transformers, Fire protection

RENEWABLE ENERGY AND OVERHEAD LINE INSTALLATION

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We buy local, we build local, we are local, but we deliver Globally” – Dion Fourie MD (MOTOR CONTROL AUTOMATION) 

The MCA Group is proud to present a full turn-key electrical and automation solution to the market from a single point of contact, which is a real differentiator over their global and local competition

-Low voltage switchboards and drives

-Medium voltage switchgear up to 22KV

-Ring main units

-Automation, instrumentation, software design and manufacturing

-Energy monitoring systems and power conditioning

-UPS systems

-Engineering and design capabilities

-Installation and construction management

-Instrumentation and cable sourcing and supply

-Electrical motor and VSD supply

-Diesel generators and change over panels

-Plant lighting supply and installation

-Condition monitoring & SLA agreements, smart monitoring solutions

-Training and commissioning services

SIte Installations

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Exxaro Belfast
about MCA Projects, low voltage assemblies, medium voltage assemblies, automation and managements systems, VDS and Electrical Motor Supply, Instrumentation and power cable supply installation, containerised, containerized solutions, Mobile E house And SKID Solution, Transformer, Duty type, and OII Type ONAN, Projects Management and Detailed Engineering

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32 Northrand Road, Corner Romeo Street, Hughes Ext, Boksburg, 1460

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