Proposal of Diesel Generator Set Power Plant
Technical Specifications of Genset Quotation for diesel genset ZBF2000S and ZBF1830S
Project profile
This project is to build a Peak shaving power plant. 23 KV Voltage,50Hz frequency.
400V of genset steps up t o 23KV via transformer. The Maximum capacity is 105MW with 1000~1300 operating hours per year.
Based on the design, the power plant consists of 60 generator sets with single capacity of standby power 2000kw,prime power 1800kW, total capacity of the power plant is 120MW.
Bi-fuel oil system is adopted; the percentage of natural gas in this system shall be not higher than 70%. Genset and its auxiliaries are integrated within 40 feet container.
Selected generator set
Three essential components, i.e. engine, generator and controller, of genset are selected based on the above technical requirement: Germany MTU for engine, Fuzhou Leroy-Somer generator and DEIF controller.
The 60 gensets shall be powered as a whole, synchronizing, load share function is required for controller, thus DEIF AGC-3 controller is selected. One controller for one unit, 12 units consists of one group, and an extra controller for one group, a main controller for the whole system of 60 units to realize synchronization and output control.
The genset has characteristics of fast starting, good ability to bear sudden load-up, low failure rate and reliable operation, energy conservation and environment protection, highly cost effective.
Diesel oil is used for operation.
Conditions for standard output power:
Ambient temperature: 40°C
Relative humidity: <90%
Altitude above sea level: <1000m
This system program meets the requirement of project, including diesel generator set, Dual fuel system, controller system, master controlled system, LV power distribution equipment, container, boosting transformer, fuel supply equipment and its auxiliaries.
Oil system is only designed to automatic oil filling system of each unit, connecting of outer fuel tank and fuel supply pipe is not including in this system.
The scope of system is equipments, excludes installation materials such as cables, pipeline, etc.
Main systems are as follows:
No. |
Name |
Module specification |
Unit |
QTY |
Notes |
1 |
Unit system |
Diesel Generator sets |
ZBF2000S Genset
Standby power:2000kw
Prime power:1800kW
Rated voltage: 400V
Rated frequency: 50Hz
Power factor: 0.8
Rated speed: 1500rpm |
/P>
Set |
60 |
Engine imported with original packing |
Microcomputer intelligent control box, auto-synchronizing control system |
AGC-3 monitor control panel: with automatic/ manual/ three remote control functions, RS232 or RS485 communication interface, synchronizing and load distribution control. |
Set |
60 |
DEIF E-Controller imported with original packing |
Circuit breaker |
frame-type |
Set |
60 |
|
Bi-fuel system |
Gas circuit & controller system |
Set |
60 |
|
Container |
40 feet container |
Set |
60 |
|
2 |
Fuel tank system |
Fuel tank |
500L |
Set |
60 |
|
Automatic oil filling system |
Oil pump, automatic controller |
Set |
60 |
|
3 |
boost |
transformer |
Boosting transformer 2500KVA |
Set |
60 |
|
5 |
|
Main control cabinet |
With group controller, main controller, PC etc. |
Set |
1 |
|
6 |
Auxiliary systems, others |
Exhaust systems, batteries, tools, materials, heater, random attachments, etc. |
Set |
60 |
|
Features of power station
a). compact structure, flexible installation site and short construction period.
Auxiliaries of genset are not complicated, small size, light weight. Diesel gensets occupy a limited area, fast construction and low investment.
Modularized system is adopted for diesel gensets, and it can be flexibly arranged based on land form, low influence by geographic restriction, and suitable for constructing in mountain area and mine area.
b).
high heat rate, low fuel consumption and low operation cost.
Low fuel consumption, i.e. 191g/kWh.
c).
fast starting and full load to be achieved quickly For single genset operation, full load can be achieved in 15s under normal condition, time required for shut down is short as well, shift from start to stop and stop to start frequently is also permitted.
d).
Easy maintenance, a little workload of regular maintenance, less staff required, overhaul interval is 24000~30000 H (depend on fuel oil quality), low operation cost.
e).
easy to assemble and easy to extend capacity Single genset capacity of diesel power plant is 2000kW, arbitrary combination of unit operation number can be achieved, with an advantage of suitable for a variety of load capacity. Diesel generator set as the power of a power plant, installed capacity is flexibly configured according to actual needs, and in the subsequent expansion of capacity, capacity of the units can be increased based on the need, the expansion access is simple and flexible, so the initial investment in construction costs are also low.
f).
With emergency start-up characteristics, (external power supply is not required, the initial energy is from the battery pack), power plant is fully operated automatically.
Arrangement of genset
The generator set uses 40feet container, arranged in 2 row outdoors, between which is main control cabinet.
Genset, transformers, oil tanks, LV cabinet, unit control cabinet and other related parts are arranged in a container.
1. general requirements
Container of rain proof type is installed outdoors, anti-corrosion, with normal repair ladder.
2.Container
The size of box is 40 feet high cube container, using integrated steel structure, Foundation for container shall be capable of bearing enough load carrying capacity, and container is made from 1.5mm electrolytic steel corrugated plate specialized for producing container, lined with steel frame. Base plate uses 4mm riffled plate, with the function of skid resistance. Drain outlet, filling inlet shall be designed. The overall container shall have the functions of rainproof, sun block, anti-pollution, shock resistance, wear resistance and good shape.
3. Layout inside the container
There are air outlets, air inlets, transformer, oil tanks, and cabinet inside rain proof container.
4. Internal structure
Control panel shall be placed near genset. Water drain hole, lube oil drain hole is designed on the foundation to facilitate the maintenance.
5
Outward opening door, louver for air intake/outlet, inspection door are designed.
6. Sound reduction system
Due the limited space inside the container, silencer is placed on the top, instead of inside, in the meanwhile, the noise shall be reduced to the minimum; the temperature of stack and silencer is high, so high temperature resistance material is used.
7. Installation and repair of genset
Gensets are arranged in the middle to ensure the stable transportation, connected to the bottom by bolts, which is convenient for dismantling when overhaul. Engine and generator use damper to connect with foundation with enough operation and repair space at both side.
8. Damping system
Several special dampers shall be placed between genset and container to reduce the vibration.
9. air intake system
The function for an air intake system is to provide clean, fluent air to diesel, there is an exhaust louver, sound reduction box with rodent-resistant net.
10. Exhaust system
Exhaust system is used for discharging air inside water tank outside, at the back of container there is an exhaust louver, sound reduction box with rodent-resistant net, there shall be enough space at the louver to ensure the ventilation.
11. inspection window
There is an inspection window on container located at operation door of control cabinet, control cabinet and rain proof container is fastened by bolts, operation door is easy operation so as to inspect the instruments inside at any time.
12. cable outlet
There is a cable outlet on container with enough space to connect to outside and sealed when not used.
13. Lighting inside container
There shall be lighting device inside the container.
14. Earthing device
4 earth points to be made.
15.Fire extinguisher
Two 2kg fire extinguishers shall be installed inside the container, each at one side.
16.Footboard
Collapsible footboard , is outside the containe, r for the sake of maintenance and water filling on the top.
17. Cable
All cables are hidden, using cable shield to protect it.
18. Emergency button
There will be one emergency button outside the container on the same side of controller to prevent accidents and cut off the power promptly and timely.
19. Paint and advertisement on the container
Surface of container is painted by antirust paint specialized for container, LOGO can be painted on the container as required.
20.hoisting of container.
The container is lifted by lifting lug.
Systems
Diesel generator set
Total capacity of power station is 120 MW, consisting of 60 units
Power
400V- 50 Hz |
Type |
ZBF2000S |
p.f.: 0.8 lagging |
KW/KVA Rated prime |
1800/2250 |
KW/KVA Rated standby |
2000/2500 |
Notes: standby power: annually operating hrs shall be less than 500hrs, it is not allowed to exceed rated power.
Prime power: annually operating hrs are not limited, one hour out of 12 hours is allowed to operate at a rate of 110% of rated power. The permissible average load rate per 12 hours is 80% of normal power
Diesel Engine
MTU engine use the most advanced ADEC electronic management system, common rail fuel injection system,turbocharger technology and double cooling technique. Compact structure, light weight, large specific power, water-cooled 4-stroke, 90°V-cylinder arrangement, turbo intercooler, wet replaceable cylinder liner, new piston design, dry exhaust manifolds, good maintainability.
GTI Bi-Fuel Systems
The Bi-fuel system utilizes ALTRONIC Inc. state- of- the- art electronic control and monitoring system which monitors critical engine and Bi-fuel System parameters and activates or deactivates gas mode according to the programmed limits. All the system equipments are mounted externally on the engine.
GTI Bi-Fuel Systems has a very rich experience, the main transformation of generating set, including caterpillar, Cummins, Detroit, Mitsubishi, Volvo, MTU, etc., And in the world successfully transform a number of small and medium peak power plants.
In some oil fields, the intermittent gas of oil Wells with instability pressure, use diesel/natural gas dual fuel generator, which can be flexibly switching between the gas and diesel, to ensure the normal work of the engine.
GTI Bi-Fuel Systems working principle
After the engine is running, open the GTI dual fuel system, the system automatically detect the parameters of each sensor, if the parameter is normal, electromagnetic valve is opened, gas pipeline to open at the same time. Gas and air is mixed in the mixer and into the engine. Increased engine power, diesel supply decreases, achieve the goal of gas instead of diesel. the types and the quality of fuel is different, replacement rate is also different. General substitution rate from 50% to 70%.
Engine thermal loads are equivalent to 100% diesel operation, Diesel engine internal structure also does not need to change.
Gas Type for Bi-fuel Operation
Natural gas of pipeline
Oil well gas
LNG
CNG
Biogas
Coalbed methane
GTI Bi-Fuel Systems characteristics
no change of engine system,All the system equipments are mounted externally on the engine. Engine body does not need to make any changes, just after the air filter inlet pipe with a gas inlet mixture, and the corresponding gas supply pipe.
no loss of power,Engine thermal loads are equivalent to 100% diesel operation,Engine power the same,The thermal efficiency the same.
the extended operation time. In the case of the same fuel, can be for a period of two to three times.
Low air requirement. Does not require high pressure air supply (1 ~ 5 psig); Also can use intermittent unstable gas source, the system has automatic monitoring function, at the time of gas anomalies can be automatically switch back to 100% diesel model, it can adapt to the instability of gas supply.
Low initial investment and convenient installation.
Fuel cost savings ( due to significant cost differential between diesel fuel and natural gas ). No occurrences of excess wear of combustion chamber components ( pistons, rings, valves, injector etc ), Cleaner burning characteristics of natural gas resulting to extended oil change intervals and time between overhaulsCleaner burning characteristics of natural gas resulting to emissions reducing, as follows:
• NOx: 15~30%
• HC: 20~80%
• PM: 20~50%
• OPACITY: 30~50%
• SOx: 50~70%
Controller monitors various engine and system parameters such as manifold air pressure and temperature, exhaust gas temperature, intake vacuum, gas pressure and engine vibration. This information allows the controller to determine when to activate or deactivate bi-fuel operation depending on engine performance, load level, ambient temperature, knock limits or gas supply pressure levels. The controller can communicate with remote engine monitoring systems via RS-232/RS-485 connection (ASCII or MODBUS protocol).
Technical parameters of ZBF2000S Diesel Genset
|
Genset Model |
ZBF2000S |
Dimension (L×W×H) mm |
7091×2200×2439 |
Weight kg |
14980 |
Standby power kVA/kW |
2500/2000 |
Prime power kVA/kW |
2250/1800 |
Rate speed rpm |
1500 |
Output frequency Hz |
50 |
Rated voltage V |
400/230 |
|
24V DC electrical starting |
Wire mode |
3-phase 4-wire(Neutral directly grounded) |
Control system |
micro-processor control system |
Damping system |
high-elasticity rubber damper |
Engine |
Engine model |
16V4000G63 |
Rate power (prime/standby) kW |
1965/2185 |
Engine type |
16 V, turbocharge |
Fuel type |
light diesel |
Fuel consumption rate g/kW.h |
191 |
Oil consumption rate g/kW.h |
0.5% of fuel consumption |
Speed regulating mode |
ADEC |
Cooling method |
Closed circulation water cooled |
MEP (mean effective pressure) bar |
20.6 |
Intake flow m3/s |
2.8 |
Exhaust flow m3/s |
5.8 |
Exhaust temperature °C |
485 |
Compression ratio |
16.5:1 |
Combustion mode |
Direct injection type |
Bore/Stroke mm |
170/210 |
Displacement L |
76.3 |
Flywheel interface size (flywheel shell\ flywheel) |
SAE00/21 |
Dimension (L×W×H) mm |
3001×1658×2154 |
Weight kg |
7700 |
Generator |
Model (single bearing) |
LSA51.2VL90 |
Rate power (prime/standby) kW |
1888/2076 |
Rated voltage V |
400/230 |
Shell protection |
IP23 |
Insulation class |
H |
Excitation system |
brushless self-excitation |
Short-circuit current capability |
300%In:10s |
Winding pitch |
2/3 |
Dimension (L×W×H) mm |
1977×1082×1395 |
Weight kg |
4995 |
Control system |
Control module |
AGC-3 |
Displayed contents |
Checking the unit data by LCD: engine three-phase voltage, three-phase current, battery voltage, frequency, speed, oil pressure, power factor, water temperature, operation time, fuel level(option), troubleshooting reasons, etc. |
Main functions |
Achievement of auto protection and failure testing: high water temperature, over-speed, high three-phase voltage, low three-phase voltage, over-load, failure start, over-frequency, under-frequency, low oil level alarm shutdown, low battery voltage alarm and user-defined alarm. Automatic synchronizing monitoring, achievement of parallel operation, connecting with gensets as well as among units |
Quotation for Diesel Genset ZBF2000S
Quotation for Diesel Genset ZBF1830S |