TABLE OF CONTENTS

1.      General

1.1    Project brief

1.2    DG set configuration

1.3    Standard & code

2.      Design Fundament

2.1    Civil Work

2.2    Fuel

2.3    Cooling Water

2.4    Electricity

3.      General Arrangement

3.1    Main building

3.2    Radiator

3.3    Oil storage

3.4    Separator and pump room

4.      System Specification

4.1    DG System

4.2    Governor system for DG

4.3    Oil storage

4.4    Fuel Circuit System

4.5    Lube Oil Circuit System

4.6    Starting Air Circuit System

4.7    Cooling Water Circuit System

4.8    Intake air and ventilation system

4.9    Exhaust gas and environmental impact mitigatory system

4.10 Steam System

4.11 Water soften system for exhaust gas boiler

4.12 Oil and water waste disposal system

4.13 Electrical System

4.13.1    H.V. system

4.13.2    L.V. system

4.13.2.1          L.V. power source for power plant

4.13.2.2          Emergency generator

4.13.2.3          DC panel

4.13.3    Control system

4.13.3.1          DG

4.13.3.2          Central control panel

4.13.4    Protection system

4.13.4.1          Diesel engine

4.13.4.2          DG electricity system

4.13.5 230kV electrical system

5.      Main equipments specifications

5.1    Diesel engine

5.2    Alternator

5.3    Heavy fuel oil separator module

5.4    Lube oil separator module

5.5    Exhaust Gas Boiler

5.6    Air compressor

5.7    Air Receiver

5.8    Diesel Generator

5.9    Radiator

5.10 S9-1000/6.6/0.44 Station transformer

5.11 Heavy Fuel Oil storage

5.12 Diesel Oil Storage

5.13 Buffer HFO Tank:

5.14 Daily Heavy Fuel Oil Tank

5.15 Daily Diesel Oil Tank

5.16 Sludge Oil Tank

5.17 Common Circulating & Booster module

5.18 HFO transfer pump

5.19 Diesel Oil transfer pump

5.20 Station batteries and battery charger panel

5.21 Oily water separator

6.      Drawings

6.1    Layout for 10X2MW HFO power plant

6.2    Fuel system

6.3    Lube oil system

6.4     Boiler and silencer arrangement

6.5     Steam and water recycle system

6.6     Starting air system

6.7     Oily water treatment system

6.8     Oily water separator

6.9     Single line drawing for power plant

 

1. General

1.1    Design input

INFORMATION REQUIRED FOR SELECTION / SIZING / DESIGN OF POWER PLANT

A SITE CONDITIONS

1) Altitude (m above Sea Level) 14 MSNM

2) Maximum Ambient Temp. (C)

3) Relative Humidity at Maximum Ambient (%)

4) Wet Bulb Temperature of the Area (C)

5) Environment (Dusty / Clean)

6) Presence of any Hazardous or ChemicallyActive Gases In Surrounding Air - NO

7) Soil Condition at site (normal, marshy, black cotton etc.)

8) Soil bearing capacity (< 15 tons/m2 or > 15 tons/m2)

9) Water table at site YES

 

B POWER REQUIREMENT (As discussed personally present conditions given)

1) Maximum Demand (kVA)

2) Minimum continuous process loads (kVA / kW) 20000KW

3) Grid Voltage and Frequency

Variation Percentage 230KV GRID TRANSSMITION LINE, 60HZ

4) Whether Independent Auxiliary Power Supply (415 V) available

5) Proposed Power Plant capacity (MW) 1MW GENERATOR X 20

 

C STEAM REQUIREMENT (IF ANY)

1) For process Steam (Quantity T/hr, pressure)

2) For air-conditioning / chillers etc (quantity T/hr., pressure)

3) For fuel heating only

4) Existing Boiler(s) details

 

D FUEL

1) Type of fuel to be used HPS / LSHS / FO / LDO / HSD / NG / BIOGAS

(Please provide specifications of fuel, in case of Gas Annexure IV shall be filled also)

2) Approximate price of fuel at site USD $ 2.00

3) Design Viscosity of Fuel handling System (180 or 380 cSt at 50 C)

4) Fuel Handling and Storage Facility at site (If any for existing Generating Sets)

 

INFORMATION REQUIRED TO DETERMINE OPERATING PHILOSOPHY

A POWER PLANT OPERATION (Continuous / Base Load / Standby / Emergency / Peaking) 8 HOURS PEAK

 

B PARALLEL OPERATION

1) With grid (Yes / No )

2) Between proposed DG Sets (Yes / No)

3) With existing DG / TG Sets (Yes / No)

Details of existing DG /TG sets (if parallel operations req.)

i) Supplier / Model / Name plate details

ii) Rating (kVA / kW)

iii) Make / Model / Type of Governor

iv) Type of Excitation / AVR

v) Synchronization Facility

 

C SPECIAL REQUIREMENTS

1) Motor Starting Duty (If any)

(If yes, please provide details wherever possible)

2) Furnace application

(If yes, please provide details wherever possible)

3) Non-linear Thyristor Loads, if any

4) Any other non-standard loads, if any

5) Voltage requirement (3.3 / 6.6 / 11 kV) 380-415

6) Water Availability (Sufficient- Cooling Towers, Scarce - Radiators)

 

INFORMATION ABOUT THE CLIENT (PURCHASER / OWNER COMPANY)

1) Annual Turnover of the Company

2) Main Product and installed capacity

3) Location of the Site

4) Availability for proposed Power plant at site

5) Contact Person at Site

Address / Telephone / Fax #

6) Whether power requirement is for existing plant /expansion project / new project

7) Duty structure (EPCG / EOU / Project Import / IPP)

8) Project Implementation Schedule

(Power Out - month / year)

9) Mode of Financing the Project OWN

10) Type of Offer Required (Feasibility Study / Indicative / Budget / Firm)

11) Cost of existing Power

(a) From Grid including Max. Demand Charges

(b) Generated from other source (DG / TG etc.)

 

Additional Information

1. What is the current project stage? Please specify the expected schedule.

2. Is the fund for the project ready? If yes, where from?

3. What is the process for awarding EPC contractor? Negotiation or public tendering?

4. Why need Chinese equipments and EPC services?

5. What is your role for this project? Developer/owner/sponsor/investor/EPC contractor/agent/consultant?

6. What type of set you need? Brand new or used?

 

1.2    Project brief

At the requirement of the Buyer, the Seller will build a 10x2MW biodiesel Power Plant for Buyer operating with biodiesel in Panama.

The power plant consists of 10 sets of diesel generators with capacity of 2000KW per set.

 

1.3     DG set configuration

The specification outlines the scope of supply for each DG set;

The DG set is driven by diesel engine model GN8320ZD8 manufactured by NBo zhongceGroup, which is the largest middle speed engine manufacturer in China;

The engine will use biodiesel oil (380cSt/50�?as fuel.

 

1.4     Standard & code

The design is according to the Chinese standard & code, in line with ISO/IEC standard. The project is designed under the merit of “advanced technology, highly efficiency, safety, economy and practicality�?

The installation and the commissioning should be in line with the above standard & code.

 

2.      Design Fundament

2.1 Civil work:

The main building, control room and pump house above the ground all adopt steel structure. The under ground portion are reinforced concrete structure.

 

2.2 Fuel:

Biodiesel is the main fuel. If HFO is used, the HFO need to be heated by the steam that supplied by steam exhaust gas boiler.

 

2.3 Cooling water:

Radiator for each generator is arranged in power plant.

 

2.4 Electricity

One 1000kVA station transformer is used to supply 440V source for the power plant.

One 400KW diesel generator is supplied as power when the whole power plant is stopped.

 

3. General arrangement:

3.1 Main building

The main building will be arranged in 2 lines:

The first line (Control room) is for the electrical control room, switchgear room, water soften treatment room and air compressor, air receiver. The second floor is for steam exhaust gas boilers and silencers, boiler is hypaethral layout. The distance of the columniation is 6 m; the span is 8 m, length is 72M and height is 5 m;

The second line (Generator hall) is for DG, lube oil tank, lube oil separator, booster, etc, the span is 18m, length is 72m; there is a traveling double girder crane (10t) in the room.

a.      Control room

The total area of control room is 576 square meters with length of 66m, width of 8m and height of 5 m. The roof of the control room is of reinforced concrete construction, and is flat roof that is convenient for installing equipments on it. One silencer and its bracket with weight of 1.2 ton are arranged for each generator, total is 10 sets, and total weight for 10 silencers is 12 tons. An exhaust gas boiler with weight of 5 tons is arranged for every three generators, total is 3 boilers, and total weight for 3 boilers is 15 tons. For each boiler, girder for bearing the weight shall be arranged.

Inside the control room, there are HV switchgear room, LV control room, water soften treatment room and air compressor room. All HV and LV cables will be connected to switchgears or control panels through cable channels in the control room.

Double deck sound insulation glazing with length of 1800 mm, width of 1500 mm, and thickness of 8 mm is installed on the control room wall facing to the alternator end of the generator. The bottom of glazing shall be 800 mm above the ground.

Ventilation for the control room adopts air conditioner.

b.      Generator hall

The total area of steel construction main building is 1296 square meters with length of 72 m, width of 18m. The distance of the columniation is 6 m. A 10 tons double girder bridge crane with span of 16.5 m is installed in the generator hall. The installing height of columniation for crane railway is 7 m, and its total height is 9.6m. The maximum height of the main building is 12.8 m.

Main equipments in generator hall:

a.      10 sets of 2MW generators

Model: 2000GF1-1A; Rated power: 2000kW; Rated speed: 600r/min; Weight for each generator: 44 tons including diesel engine 25 tons, alternator 16 tons and engine frame base 2.8 tons.

b.      One set of 400kW emergency diesel generator

Model: 400GF; Rated power: 400kW; Rated speed: 1000r/min; Total weight: 8.5 tons

c.       1 set of fuel booster module

Weight for the fuel booster module; 2.3 tons.

d.      5 sets of lube oil separator modules

Weight for each lube oil separator module: 400kg.

 

3.2 Radiator

10 outdoor radiators are arranged besides the main building.

 

3.3 Oil storage

Total area for oil storage is 1254 square meters with length of 66 m and width of 19 m. The following oil storages are arranged:

a.      Two heavy fuel oil storages with volume of 1000 cubic meters, storage diameter of 11.5 m, height of 10.5 m, dry weight of about 80 tons and total weight of 1080 tons for each oil storage. The intensity of foundation shall be fully considered.

b.      One diesel oil storage with volume of 300 cubic meters, storage diameter of 7.6m, height of 8 m and total weight of 350 tons. The intensity of foundation shall be fully considered.

c.       Two buffer heavy fuel oil tanks with volume of 100 cubic meters, storage diameter of 5.73 m, height of 5 m and total weight of 120 tons.

d.      One daily HFO tank, one daily DO tank and one sludge oil tank with volume of 50 cubic meters, storage diameter of 3.82 m, height of 4.5 m and total weight of 55 tons for each oil tank.

Fireproofing wall with height of 1.6 m is arranged around the oil storage, earthing for avoiding thunder-strike shall be considered for the oil storage.

 

3.4 Separator and pump room

The total area of separator and pump room is 104 square meters with length of 13 m, width of 8 m, and height of 5 m.

Main equipments in the separator and pump room:

a.      Three set of separator modules;

b.      Two HFO transfer pumps and DO transfer pumps

 

4. System specifications:

4.1.     DG system:

According to the power capacity 20MW, the project plan configures 10 units of diesel engines and generators.

Rating of the D.G. set 

Under above mentioned site conditions

-----------------------------------------------------------------------------------------------

       Rating at       Alternator       Rating at

       engine         efficiency       alternator

       crankshaft                     terminal(MCR)

       KWm             ( % )        KWe         KVA(0.8 pf)

-----------------------------------------------------------------------------------------------

Nominal        2206             94         2000      2500

Running   

-----------------------------------------------------------------------------------------------

Note : COP rating will be 90 % of MCR

 

4.1.1.      2MW diesel engine:

Technical particulars for the diesel engine are as follows:

Number of cylinders                8

Arrangement of cylinders           In Line

Bore (mm) X Stroke (mm)           320 X 380

Type                                            4-stroke, direct injection, turbocharger, after cooler

Rotational speed                        600 RPM

Mean effective pressure            18 Bar

at rated power & speed

Mean piston speed                  7.6 m/sec.

Rotation seen from flywheel        Clockwise.

Swept volume per cylinder         30.578 litres

Combustion chamber volume        2.352 litres

Compression ratio                   13:1

Max. combustion pressure         125 bar

(at rated power/speed)

 

The engine should be capable of accepting a sudden load as per the guidelines in ISO-8528-5-1993(e). As per this standard, the maximum sudden load increase stages are

 

         Baseload %     Sudden load   increase to %

--------------------------------------------------------------------------------

1st Stage          0%          40                40%

2nd Stage             40%         30                  70%

3rd Stage       70%         20                  90%

4th Stage       90%         10                  100%

During each of the above-mentioned stages of sudden loading, the transient speed drop will be restricted to a maximum value of 10% of the rated speed. 

 

4.1.2.      Alternator

The Alternator is self-excited, brush-less type in two bearing construction with single shaft extension and IP 23 enclosure. The alternator is fitted with bearing temperature detectors.

- Rated output kVA                                          2500 KVA

- Power factor                                             0.8 lag

- Max. Alternator output at site                   2000 KW

- Duty                                                         Continuous

- Rated speed                                               600 RPM

- Rated voltage                                          6600 V

- Efficiency at 100% load and 0.8 PF             �?4 %

- Direction of rotation                                 clockwise

- Number of poles                                             12

- Rated frequency                                             60 Hz

- Over-speed                                                    20% for 2 minutes

- Overload capacity and duration                10%, for max. 1 hr in every 12 hrs

- Insulation class                                         F

- Enclosure                                                IP 23

- Temp. rise class                                       F

- Excitation and AVR type                           Brush-less, AVR

- Connection                                              Star

 

4.2 Governor system for DG

Woodward 2301D digital control and UG15 actuator are adopted for load sharing and speed control of diesel generator.

The 2301D is a microprocessor-based digital control. The control is housed in a sheet-metal classis and consists of a single printed circuit board. The 2301D is configured using a computer with Woodward Watch Window software. The computer connects to the 2301D through a 9-pin connector (RS 232 port). The control operates from a 24Vdc supply. The actuator output, one analog input, and one analog output are configurable. The 2301D features dual dynamics and soft load transfer, to and from a bus. The 2301D includes one load sensor circuit, one actuator driver, one MPU speed sensor, one configurable analog output, one configurable analog input, eight discrete inputs and four discrete outputs. The 2301D operates within a range of �?0 to +70�?

The 2301D provides load sharing and speed control of diesel generator. The 2301D has four operating modes �?speed control, isochronous load sharing, droop base load, and isochronous base load.

Woodward UG-15 is a hydraulic powered electric actuator. The UG-15 provides the muscle for 2301D. The UG-15 takes a given electrical input signal and converts it to a proportional hydraulic output-shaft position to control engine flow.

 

4.3 Oil storage

There are two 1000m3 HFO storages, two 100m3 buffer HFO tanks, one 300m3 DO storage, one 50m3 daily HFO tank, one 50m3 daily DO tank and one 50m3 sludge oil tank. HFO separator double module and fuel pumps are installed in the separator and pump room.

Heavy fuel oil transported by fuel truck (about 30 ton) will be pumped to two HFO storages and two buffer HFO tanks. Two HFO transfer pumps are installed in the room, one is for standby. Filter and flow meter are also installed before the HFO transfer pumps. HFO in the two HFO storages can be transferred to the buffer HFO tanks by the two pumps.

Diesel oil transported by fuel truck (about 30 ton) will be pumped to DO storage and daily DO tank. Two DO transfer pumps are installed in the room, one is for standby. Filter and flow meter are also installed before the DO transfer gear pumps. DO in DO storage can be transferred to the DO daily tank by the two pumps.

For all HFO storages and tanks and sludge tank, steam coil pipes are installed inside and thermal insulations are provided outside.

Fuel temperature in HFO storage is recommended to be 50-60 centigrade degree, fuel temperature in buffer HFO tank to be 70-80 centigrade degree. The buffer HFO tanks are used for pre-separation of sludge and water contained in HFO and providing a suitable constant HFO temperature. Gravitational settling of water and sediment in HFO is an extremely slow process due to small density difference between HFO and the sediment. A large fuel oil surface area and a low viscosity are needed for the settling process. The volume of each buffer HFO tank is 100m3, which is enough for 24 hours continuous operation at rated load.

HFO in buffer HFO tank will be pumped to three separator modules. The separating capacity for each separator unit is 3000 kilogram one hour. When two separators work together, the separating capacity is 6000 kilograms one hour. For whole power plant, the maximum HFO consumption one hour is about 3000 kilograms. The clean HFO will be pumped to daily HFO tank, and the sludge oil will be pumped to sludge oil tank through the sludge oil pump installed on separator module.

Heavy fuel oil in daily HFO tank and diesel oil in daily DO tank will be pumped to booster module in generator main building.

 

4.4 Fuel Circuit system

4.4.1 Type of fuel:

The engines are suitable for operation on DO (Diesel Oil) / HFO (Heavy Fuel Oil or Furnace Oil with maximum viscosity 380 cSt at 50 deg. C.);

When starting or stopping the engine DO (Diesel Oil) is used as fuel. When the water temperature at inlet to engine exceeds 60 degree centigrade, and the HFO (Heavy Fuel Oil) is heated to the required temperature, the fuel can be changed from DO to HFO through a changeover oil tank.

Equipment fitted on the engine:

 

-      Individual fuel injection pump for each cylinder with fuel rack & linkages.

-      Individual injector fitted on each cylinder head.

-      High-pressure injection pipes

-      Main fuel rails for feeding and return.

-      High-pressure pipe connection for each cylinder

Equipment delivered loose:

 

1)                  Three HFO separator modules

2)                  Two fuel viscosity control modules (booster) consisting of:

Two electric motor driven fuel feed pump (one for working, one for standby);

Two electric motor driven fuel booster pump (one for working, one for standby);

One duplex type coarse filter;

One pressure-regulating valve;

One steam heater for HFO;

One flow meter for HFO;

One 3 way fuel changeover valve;

One viscometer & temp controller;

One emergency pressure safety valve;

One duplex type fine filter;

one mixing vessel with safety valve;

One pressure-regulating valve in fuel return;

3)   Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses,        supports, etc as necessary.

Fuel consumption:

The hourly rate of fuel consumption per Kilowatt Power delivered at the crankshaft flange at rated power & speed (after running in of the engine & for engine with driven raw water, fresh water & lube oil pumps) is 198g/kWh, when engine operates at Maximum Continuous Rating (MCR).

 

FUEL CONSUMPTION (with 3 driven pumps)

====================================================

         GN8320ZD8           Consumption at  

                            (600 RPM)             engine Cr.shaft

                                                   g/kWh

====================================================

                100% Load              198.00

SITE       -----------------------------------------------------------------------------

          75% Load                202.00

CONDITION-------------------------------------------------------------------------

             50% Load                211.00

====================================================

The values are subject to a 3% tolerance and apply when burning fuel with a net calorific value of 10,200 KCal/Kg minimum.

CLIMATIC CONDITIONS

ISO Conditions

Air temp. to turbocharger inlet              25 deg. C

Atmospheric pressure                     750 mm Hg

Relative humidity                         60 %

Water temp. at charge air cooler inlet       25 deg. C

Site Conditions (Assumed)

Air temp. to turbocharger inlet              45 deg. C

Atmospheric pressure                     750 mm Hg

Relative humidity                         60 %

Water temp. at Radiator outlet             52 deg. C

 

The heavy fuel oil from daily HFO tank and diesel oil from daily DO tank will be pumped to the mixing vessel on the booster module through two fuel feed pumps. After heated by steam, the heavy fuel oil (or diesel oil) with constant viscosity about 12-15 cst will be pumped to fuel main pipe. The booster module is used for controlling viscosity and supplying fuel for generators. There are two booster modules installed in the main building, fuel-supplying capacity for each booster module is 5000 kilograms one hour (Maximum feed capacity is 10000kg one hour, return oil is 5000kg one hour), one works, one is for standby. The two fuel main pipes are connected with valve, which is used for emergency in case of one booster module failure.

Return oil from each generator will back to the mixing vessel through return main pipe, the two return main pipes are also connected with valve.

 

4.5  Lube oil circuit system

Oil sump capacity (ltr)

The engine is equipped with a dry sump attached to the bottom of the crankcase. The lube oil for the engine is stored in a separate tank positioned away from the engine. This arrangement offers much more reliability than the wet sump arrangement & also increases the time between oil changes by lube oil separator module.

The total oil capacity of this lube oil tank is 2000 ltrs.

The average lube oil consumption is 1.6 g/kWh (+/- 0.2 g/kWh) at MCR at crankshaft for a well-run engine.

One lube oil separator module is arranged for two generators, total in the main building are five lube oil separator modules. Lube oil separator is used for cleaning lube oil and prolong usage time.

Equipment fitted on the Engine:

-      One engine driven lube oil supply pump

-      One engine driven lube oil transfer pump

-      One pressure-regulating valve

-   One lube oil thermostatic valve (option)

-      Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses, supports, etc as necessary.

Equipment delivered loose:

-      10 tanks for lube oil (2000 ltrs capacity) with interconnections to the engine

-      10 electric motor-driven lube oil-priming pumps

-      10 manual lube oil-priming pumps

-      10 lube oil coolers

-           10 centrifugal lube oil filters (FLL75 bypass type)

-           10 lube oil duplex type filters

-           5 lube oil separator modules

-          Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses,    supports, etc as necessary.

 

4.6 Starting air circuit system

The DG is started by the compressed air.

Two air compressors, two 2.5m3 air receivers and one top up are arranged for the power plant, the capacity of each air receiver is 2500 liters, which is enough for starting one generator 30 times without intermediate refilling of the receiver.

High-pressure compressed air about 3 Mpa from the air receivers will be sent to generators through air main pipe, and also be sent to exhaust gas boilers for cleaning chimney, to lube oil separator modules, HFO separator modules and booster modules through pressure reducers for control air.

Equipment fitted on the engine:

Compressed air starting equipment including:

-      One rotary distributor

-      One air-starting valve in each cylinder head

-      Connecting air piping on the engine

Equipment delivered loose:

-      Two air compressors

-          Two air receivers

-          One top up

-          Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.

 

4.7 Cooling water circuit system

Radiator made by GEA is arranged for each generator, and an electric water pump is arranged for the water circuit system.

Drawn by the electric water pump from the radiator, the cooling water flows to the air cooler, and to the injector cooling oil cooler and to the lube oil cooler, and then enters the inlet water main pipe and the turbocharger. The cooling water is discharged out through the outlet water main pipe. Finally the water is cooled in the radiator.

Equipment fitted on the engine:

-            One lube oil cooler

-            One injector cooler

-      One water-cooled charge air cooler

Equipment delivered loose:

-          10 radiators (outdoor, GEA)

-          10 electric water pumps

-          Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.

 

4.8 Intake air and ventilation system

The air intake system is equipped with air filtration (ABB type installed on the engine) to clean air.

For 10 diesel generators, air consumption is 125000m3/h. 10 axial-flow explosion-proof fans opposite to each generator are arranged for the main building on the engine side. Airflow capacity for each fan is 15870m3/h; total airflow capacity is 158700m3.

The axial-flow fans are used for supplying air for the generators and reducing temperature in the engine room through convection. The quantity of heat dissipated from the generators is about 4200 MJ/h. The air will be discharged through natural ventilation on the upper side of the main building.

 

4.9 Exhaust gas and environmental impact mitigatory system

Air pollution prevent

All diesel engines for the power plant are acquired international air pollution prevent certificate according to the provisions of Annex �?of the international Convention for the Prevention of Pollution, 1973, as modified by the Protocols of 1978 and 1997 relating thereto and of the Technical Code on Control of Emission of Nitrogen Oxides From Marine Diesel Engines.

Emission data as follows:

Applicable Nox emission limit (regulation 13 of Annex �?: 12.5g/kWh

Engine’s actual Nox Emission Value: 9.69g/kWh

Noise

The mechanical noise beside the diesel engine at a distance of 1 m is 112 dBA. The mechanical noise will be proofed and reduced by the main building.

The exhaust gas noise is reduced through a residential type silencer to 70dBA at a distance of 1 m.

The exhaust gas from diesel generator flows to exhaust gas pipe (DN400), pass a tee joint, and then divides two ways. One flows to silencer through a butterfly valve, another flows to exhaust gas boiler. When the exhaust gas boiler works, the butterfly valve for silencer will close and the butterfly valve for exhaust gas boiler will open, and then exhaust gas will vent from the chimney on the boiler. When the boiler cannot work normally or the boiler need to be stopped, the butterfly for boiler will close and the butterfly valve for silencer will open, and then exhaust gas will vent from the chimney on the silencer.

Three steam exhaust gas boilers are arranged for the power plant, each one will connect with three diesel generators. One exhaust silencer (Residential type) is fitted to the each generator.

Equipment fitted on the engine:

-      Lagged set of exhaust manifold with expansion bellows

-      One ABB turbocharger.

-      Exhaust outlet connection with expansion bellow.

Equipment delivered loose:

-          10 exhaust silencers

-          3 exhaust gas boilers

-          Insulation /lagging/cladding for exhaust ducting

-          Complete interconnecting piping with flanges, fasteners, t-joints, butterfly valves, bosses, supports, etc as necessary.

 

4.10 Steam system

Three exhaust gas boilers are arranged on the roof of control room. Heat exchange area for each boiler is 67 m2, steam capacity for each boiler is 700kg one hour at 170 degree centigrade and 0.7 Mpa. Steam from boilers will flow to steam main pipe and divide to separator and pump room, oil storage and main building through main steam distributor and steam distributors. The main steam distributor is located on the roof of control room, and other steam distributors are located beside the equipments need to be heated.

Equipments for steam system:

-          3 exhaust gas boilers

-          6 water feed pumps

-          4 Steam distributors

-          Insulation /lagging/cladding for steam pipes

-          Complete interconnecting piping with flanges, fasteners, t-joints, valves, bosses, supports, etc as necessary.

 

4.11 Water soften system for exhaust gas boiler

One water soften equipments are arranged for the power plant, water treatment capacity is 2000kg one hour.

The water soften equipment adopts resin exchanger treatment system.

Equipments for water soften system:

-          1 water soften equipment

-          2 water feed pump

-          One water tank

-          Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.

 

4.12 Oil and water waste disposal system

Oily water will be collected in an oily water pond through water channel in the power plant. An oily water separator module is arranged to separate oil from the oily water. The oily water treatment capacity for the separator module is 5 cubic meters one hour. The oil content for the treated water is 10 ppm, and can be drained directly. The oil separated from the oily water will be collected in the sludge oil tank.

 

4.13 Electrical system

4.13.1    H.V. system

Ten 2MW/6.6kV HFO generators will work in parallel and supply electricity to one 6.6KV bus-bar, and feed to one 25MWA/230kV main transformer through one outgoing panel.

One 1000kVA station transformer is used to supply 440V source for the power plant.

One 400KW diesel generator is supplied as power when the whole power plant is stopped.

 

6.6kV generator system

Ten 2MW/6.6kV diesel generators are arranged for the power plant. For each one generator, the standard configure includes one switchgear for generator output and potential transformer, one control and operation panel (COP) and one local control desk (LCD).

The neutral of the generator is earthed through resistor. As requirement of the protect system, two neutral resistor panels are configured for the power plant earthing system. Five Gen-set configure with a resistor connecting panel, which comprises of 5 knife switch to select the first feeding generator. Only one generator can connect to the resistor by the knife switch for the reason of the circumfluence current among generators. There has a zero sequence current transformer configured in the Gen-set switchgear, to protect the earthing fault in the cable between generator terminal and the CT.

All , ten generators are connected with a single bus-bar. A 6.6kV bus-bar PT panel is arranged for parallel operation. All 6.6kV H.V. panel adopt KYN28A-12 metal-enclosed removable switchgears, the switch for generator switchgear adopts VS1 vacuum circuit breaker (with truck), its rated current is 630A, and rated short-circuit breaking current is 31.5KA.

 

Generator HV panels

The generator connects to the bus-bar, by vacuum circuit breaker in the generator switchgear.

Major Components in generator switchgear:

1)                  3 pole truck type DC/AC 220V electrically operated motor energized VS1 Vacuum Circuit Breaker

2)                  Metering / Protection CT and PT

CT type: CT LZZBJ9-6.6 150/5A with two windings for each phase

Two CTs are installed in the generator switchgear. One CT is for current and power measuring (phase A and C) and excitation adjusting (phase B); another is for 2301D load sharing controller.

PT type: one REL-6.6 with two windings for each phase

One group of windings in potential transformers is star connected for measuring and protection system. Another group of windings is triangularly connected for single phase earthing protection.

3)                  Digital integrated relay

DMR-362 digital integrated relay is adopted for gen-set protection, which is used for alternator protection, switch control, monitoring, measuring and display.

The following functions and protection can be carried out on the relay:

-          Differential

-          Voltage locked over current

-          Reverse power

-          Over current

-          Single phase Earthing

-          Over voltage

-          Low frequency

-          Over frequency

-          Over load

-          Accurate measuring of all operation parameters such as power, voltage, current, frequency, power factor and others

-          Display the conditions of all switches

-          Running record and failure storage

4)                  Local / Remote control selector

5)                  VCB ON/OFF

6)                  DSSX25 kWh and kVarh meter

 

Potential transformer panel

Major Components in PT panel:

1)      Fixed PT installation truck with arrester.

2)      PT type: one REL-6.6 with two windings for each phase

One group of winding in potential transformers is star connected for measuring and protection system. Another group of winding is triangularly connected for single phase earthing protection.

 

4.13.2    L.V. system

The auxiliary equipments for generator include 10 radiators (33KWx10), 10 water pumps (18.5kWx10), 2 air compressor motors (18.5kWx2), 5 lube oil separator motors (2.2kWx5), 2 boosters (7.5kWx2) and one DC power source panel (4kW).

The auxiliary equipments for power plant include 2 HFO pump motors (18.5KWx2), 2 DO pump motors (18.5KWx2), 3 HFO separator modules (11kWx3), 6 boiler water feed pump motors (2.2kWx6) and one soft water pump motor (3kW).

The lighting and air conditioner system is about 30kW, all lighting equipments are considered during civil work.

The fire fighting system includes 2 fire-fighting pumps (22kWx2) and one water feed pump (7.5kW). All fire-fighting equipments are considered during civil work.

The maintenance system includes one 10T double girder bridge crane (10kW) and maintenance electrical boxes (total 50kW).

 

4.13.2.1  L.V. power source for power plant

Two L.V. power sources are arranged for power plant. One is supplied with a station transformer (1000KVA/6.6kV/0.44kV), another is supplied by a emergency diesel generator (400kW/0.44kV) when the whole power plant is stopped.

 

4.13.2.2   Emergency generator

The diesel generator is used as emergency power source for the power plant.

 

4.13.2.3   DC panel

The power supply of control plant, protection, signal, automatic device and trouble lighting adopts 200AH direct current electrical source system.

220/24V DC battery charger of suitable capacity along with Lead acid type rechargeable batteries (12 V DC) is used. Charger is fully automatic, with float and boost charging facility. One set of DC/DC transfer module with 60A capacity for 24V output.

Major Components in the DC panel

1)                  Source inspect and change over module

2)                  Chargers and booster module

3)                  12V batteries and battery detect unit

4)                  AC/DC ammeters, voltmeters

5)                  LCD operation screen

6)                  Over load / short circuit / earth fault

7)                  Over voltage

 

4.13.3    Control system

4.13.3.1  DG

For each one generator, one control and operation panel and one local control desk are supplied.

 

Gen-set control and operation panel

The control and operation panel in the control room provides necessary Monitoring, Control and Protection functions for the DG set. It controls the Gen-set running according to the program set in PLC. All Gen-set’s running parameters such as voltage, current, power, power factor, frequency, and speed can be displayed on it.

Major Component in console

1)      Control PLC

2)      Speed Governor controller

3)      Automatic Voltage Regulator

4)      Engine Frequency Monitoring Unit

5)      Meters

Ammeters (3 nos.)

Voltmeter with selector switch

Power meter

Frequency meter

PF meter

Analog Excitation fundamental ammeter

Analog Excitation harmonics ammeter

Counter for running hours

6) Operation and indicators

Push buttons, change over switches

VCB engaged indication,

Engine start permission indication

Excitation change over switch

DG VCB ON/OFF

DG VCB Trip and alarm indication

Engine Idling/Rating

Engine start

Engine normal and emergency stop

7) AVR

The integral TWL-ND AVR is designed for the TFW generator specially. It configures with stability adjusting, voltage adjusting, and gen-set paralleling reactive power sharing adjusting.

Input capacity         AC 230V

Compare voltage      AC 100V from PT AC

Current signal         CT 5A from CT B

Max. Output           DC.100V, 10A

Trigger Type          Alternator exciter Remanence

Accuracy             ±1%

Am. Temp            -40~+60�?/DIV>