Power Station Energy Storage Expansion Project
Papua New Guinea Photovoltaic Power Plant 5MW/10MWh Energy Storage System Expansion Project – YB-1000 Huabian and Complete Equipment Procurement Project
Photovoltaic power station energy storage expansion in Papua New Guinea with 5MW/10MWh system, enhancing grid stability and green energy transmission.
Project Overview
The photovoltaic power plant is located near the capital of Papua New Guinea , an area with a weak power grid infrastructure and extremely high requirements for power supply stability. To address the intermittent fluctuations in photovoltaic power generation, the owner initiated an expansion project, adding a battery energy storage system with a total capacity of 5MW/10MWh .
This project aims to procure key equipment connecting energy storage battery stacks to the local 11kV power grid. KeRun Intelligent Control Co., Ltd. will serve as the core supplier, providing YB-1000 prefabricated substations (Huabian) and supporting high and low voltage switchgear to ensure the efficient and stable transmission of green energy to the PNG national power grid.
Equipment List and Quantity Logic
To ensure flexibility and redundancy for the 5MW total capacity, we opted for a “modular distributed” configuration instead of a single large-capacity transformer. The equipment consists of the following:
Part 1: Core Substation Unit (YB-1000 Huabian)
This is the heart of the system. We have configured 5 YB-1000-11/0.4 prefabricated substations.
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Quantity Logic: The 5MW total power is split into 5 independent 1MW storage arrays. Each array is equipped with a 1000 kVA Huabian transformer to boost the voltage for that unit.
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Key Parameters: Rated capacity 1000 kVA; High-voltage side 11kV; Low-voltage side 0.4kV; Frequency 50Hz; Connection group Dyn11.
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Special Process: Given the island environment, the outer shell has an IP54 protection rating, with a C5-M heavy-duty anti-corrosion coating.
Part 2: High Voltage Combiner Unit (KYN28-12 Medium Voltage Switchgear)
To connect the 5 Huabian transformers’ output to the grid, we need 7 KYN28-12 armored withdrawable metal-enclosed switchgear units.
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Quantity Logic and Function Allocation:
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2 Incoming line cabinets: Receive power from the five Huabian transformers.
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1 PT cabinet: For voltage transformer metering and system protection.
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1 Bus tie cabinet: Connects sectional busbars for enhanced supply reliability.
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3 Outgoing switchboards: Transmit electrical energy to the PNG grid (PPL Grid) main substation.
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Part 3: Low-Voltage Distribution Units (GCS/GGD Series)
As part of the low-voltage side support within Huabian, 10 low-voltage switchgear cabinets are required.
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Quantity Logic: Each YB-1000 Huabian integrates 2 low-voltage switchgear panels (1 incoming line panel and 1 reactive power compensation panel). The 5 Huabian transformers together require 10 panels.
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Configuration: Schneider or ABB core components ensure precise connection with the PCS (energy storage converter) on the 400V side.
Solution Design Logic and Principles
Our solution follows the strict logic of “distributed voltage boosting and centralized current merging” based on the characteristics of photovoltaic + energy storage:
Distributed Voltage Boosting (Risk Reduction):
The DC power from the photovoltaic panels or cells is inverted to 400V. We use five decentralized YB-1000 transformers to step up the voltage directly to 11kV near the battery stacks. This design reduces heat loss in cables due to low voltage and high current, while also achieving N-1 redundancy. If one transformer fails, the other four can continue operation with only 20% loss in capacity, avoiding a complete power outage.
Factory Prefabrication (Adapting to Local Conditions):
The YB-1000 uses a prefabrication system. All high and low-voltage switches, transformers, and communication equipment are pre-installed and commissioned before leaving the factory. Once delivered, only simple foundation installation and external cable connections are required. This is crucial for PNG, where skilled electrical workers are scarce.
Research and technological insights into the characteristics of the PNG market.
Prior to designing this project, KeRun Intelligent conducted in-depth technical research on the Papua New Guinea (PNG) market:
- Harsh climate challenges : The region experiences consistently high temperatures (average above 30°C), high humidity (>85%), and intense marine salt spray. Ordinary transformers operating here will rust and leak oil in less than two years.
- Our insights and solutions : We abandoned ordinary cold-rolled steel sheets and instead used weather-resistant steel specifically for containers as the outer shell of the equipment, and adopted a three-layer spraying process to ensure that the equipment does not rust in a salt spray environment.
- Unique power grid standards : The PNG power system is heavily influenced by Australian Standards (AS/NZS) and has extremely high requirements for frequency stability.
- Our insights and solutions : We strictly locked the transformer frequency at 50Hz and expanded the tap changer’s adjustment range to ±2 x 2.5% (5 levels in total). This is wider than the conventional standard, enabling us to easily cope with the large voltage fluctuations that often occur in the local power grid and protect the energy storage equipment from tripping.
Advantages and Selling Points of KeRun Products
Intelligent Operation and Maintenance System:
The equipment is equipped with an industrial-grade IoT gateway that monitors transformer oil temperature, oil level, and gas pressure in real time. Data is uploaded to the cloud, enabling remote monitoring from Port Moresby via mobile phones. This “remote early warning” function is a significant selling point for areas with limited maintenance resources.
High Overload Tolerance:
Considering the instantaneous high current surges during peak shaving, we upgraded the transformer coil insulation material. This enables the transformer to operate safely for 4 hours at 120% load, with short-circuit tolerance 30% higher than the national standard.
Ultra-Compact Design:
The YB-1000 has a compact design, occupying only 30% of the space of a traditional civil engineering station. This significantly reduces land leveling and concrete pouring costs.
Precautions for Purchasing Transformers
Due to the unique nature of customized heavy-duty power equipment and cross-border trade risks, KeRun implements a strict and transparent business policy:
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Trade Terms: We support EXW or FOB only. Once the goods cross the ship’s rail, the buyer bears risks for marine insurance, customs clearance, and inland transportation.
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Payment Terms: We enforce a strict “payment before delivery” policy to ensure production scheduling and fund security.
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Advance Payment: The buyer must pay 20%-40% of the total contract amount as an advance before raw material procurement.
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Payment upon Delivery: After factory acceptance (FAT), the buyer must settle the remaining balance before shipment. We do not accept cash on delivery or deferred payments via letter of credit.
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Why Choose KeRun Intelligent Control Co., Ltd.?
KeRun was chosen for this critical project based on three core reasons:
“Critical Infrastructure” Delivery DNA:
KeRun has extensive experience supplying state grids and large hydropower stations. We bring this “waterworks-level” rigor to photovoltaic energy storage. In regions where equipment failure is difficult to repair, KeRun products’ “maintenance-free” nature and “zero-failure record” provide the greatest safety guarantee.
Absolute Control over the Supply Chain:
Unlike assembly plants, KeRun controls the entire industrial chain, from sheet metal processing to coil winding. In today’s volatile international supply chain environment, we guarantee 100% on-time delivery, essential for photovoltaic projects where revenue is calculated daily.
“When in Rome, Do as the Romans Do” Approach:
We did not simply sell standard products. Instead, we customized temperature control systems and anti-corrosion processes for high-temperature and high-humidity environments. Our deep understanding of local standards and environmental challenges shows that KeRun is not just a supplier but a trusted technology partner.