40MW(20x2MW) power plant
Project Design Specifications
Jointly by:
China National Electric Wire & Cable Imp./Exp. Corp.
Oct., 2008
TABLE OF CONTENTS
1. General
1.1 Design input
1.2 Project brief
1.3 DG set configuration
1.4 Standard & code
2. Design Fundament
2.1 Civil Work
2.2 Fuel
2.3 Cooling Water
2.4 Electricity
3. General Arrangement
3.1 Generator hall
3.2 Fuel storages
4. System Specification
4.1 DG System
4.2 Governor system for DG
4.3 Fuel Circuit System
4.4 Lube Oil Circuit System
4.5 Starting Air Circuit System
4.6 Cooling Water Circuit System
4.7 Intake air and ventilation system
4.8 Exhaust gas and environmental impact mitigatory system
4.9 Steam system
4.10 Water treatment system
4.11 Oil and water waste disposal system
4.12 Electrical System
4.12.1 H.V. system
4.12.2 L.V. system
4.12.2.1 L.V. power source for power plant
4.12.2.2 Emergency generator
4.12.2.3 DC panel
4.12.3 Control system
4.12.3.1 DG
4.12.3.2 Central control panel
4.12.4 Protection system
4.12.4.1 Diesel engine
4.12.4.2 DG electricity system
5 Main equipments specifications
5.1 Diesel engine
5.2 Alternator
5.3 Emergency Diesel Generator
5.4 Cooling tower
5.5 S9-1250/11/0.4kV station transformer
5.6 Station batteries and battery charger panel
5.7 Heavy fuel oil separator module
5.8 Lube oil separator module
5.9 Exhaust gas steam boiler
5.10 Common Circulating & Booster module
6 Drawings
6.1 Layout for 40MW (20x2MW) power plant
6.2 Single line drawing for 40MW power plant
6.3 Fuel system
6.4 Lube oil system
6.5 Cooling water system
6.6 Starting air system
6.7 Steam system
1. General
1.1 Design input
INFORMATION REQUIRED FOR SELECTION / SIZING / DESIGN OF POWER PLANT
A SITE CONDITIONS
1) Altitude (m above Sea Level)1200m
2) Maximum Ambient Temp. (° C) 42oC
3) Relative Humidity at Maximum Ambient (%)
4) Wet Bulb Temperature of the Area (° C)
5) Environment (Dusty / Clean) Dusty
6) Presence of any Hazardous or Chemically Active Gases In Surrounding Air No
7) Soil Condition at site (normal, marshy, black cotton etc.) normal
8) Soil bearing capacity (< 15 tons/m2 or > 15 tons/m2)
9) Water table at site
B POWER REQUIREMENT (As discussed personally present conditions given )
1) Maximum Demand (kVA) 40 MW
2) Minimum continuous process loads (kVA / kW) 38 MW
3) Grid Voltage and Frequency 11 kV 50 Hz
Variation Percentage
4) Whether Independent Auxiliary Power Supply (415 V) available
5) Proposed Power Plant capacity (MW) 40 MW
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 R 5.50 per L
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)
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)
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 Rustenburg South Africa
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 Anglo Platinum
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. Starting to build plant in 2009, need generators end of 2010
2. Is the fund for the project ready? If yes, where from? Anglo Platinum
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? Brand new
1.2 Project brief
At the requirement of the Buyer, the 40MW HFO power plant consists of 20 sets of 2MW generators at one site, operating with heavy fuel oil, total output to be 40MW.
The proposed stationary power plant is designed for base load (cop) operation and is intended for power generation.
The stationary power plant is designed to use heavy fuel oil as the main fuel, diesel oil is used as alternative fuel and for starting and stopping the generator.
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;
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 Generator hall
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
Heavy fuel oil is designed as main fuel for the power plant.
2.3 Cooling water
One cooling tower for each generator is arranged in power plant.
2.4 Electricity
One 400KW diesel generator is supplied as power for generator station when the generator station is stopped. One 1250kVA station transformer is used to supply 400V source for generator station.
3. General arrangement
3.1 Generator hall
a. Main building
The total area of steel construction main building is 2700 square meters with length of 150 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. There is a traveling double girder crane (10t) in the main building.
Main equipments in generator hall:
Twenty 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.
One set of 400kW emergency diesel generator
Model: 400GF; Rated power: 400kW; Rated speed: 1000r/min; Total weight: 8.5 tons
Three sets of fuel boosters
Three air compressors and two air receivers
Twenty lube oil tanks
Five sets of lube oil separators
One lube oil service tank (high positioned)
b. Control room
The total area of control room is 1200 square meters with length of 150m, 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 20 sets, and total weight for 20 silencers is 24 tons.
Four exhaust gas boilers are arranged on the roof, and total weight for 4 boilers is 36 tons. For each boiler, girder for bearing the weight shall be arranged.
Inside the control room, there are HV switchgear room, LV control 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.
c. Water pond
Two water ponds are arranged besides the main building. The water pond is of reinforced concrete construction with length of 57.4m, width of 4 m, and height of 3 m. The wall thickness of the water pond is 0.3 m.
20 cooling towers are installed on water ponds.
Cooling tower specifications:
Model: GBL-100; Fan diameter: 2000mm, Fan motor: 5.5kW, Dry weight: 1800kg, Wet weight 2360kg. Water supply and drain are designed for the two water ponds.
3.2 Oil storages
3.2.1 Oil storages
Total area for oil storage is 2452.5 square meters with length of 98.1 m and width of 25 m. The following oil storages are arranged:
a. Two heavy fuel oil storages with volume of 3000 cubic meters, storage diameter of 17.2 m, height of 15 m, dry weight of about 200 tons and total weight of 2700 tons for each oil storage. The intensity of foundation shall be fully considered.
b. One heavy fuel oil buffer tank with volume of 300 cubic meters, storage diameter of 7.6 m, height of 7 m, dry weight of about 30 tons and total weight of 330 tons.
c. One heavy fuel day tank with volume of 300 cubic meters, storage diameter of 7.6 m, height of 7 m, dry weight of about 30 tons and total weight of 330 tons. The intensity of foundation shall be fully considered.
d. One diesel oil storage 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. The intensity of foundation shall be fully considered.
e. One diesel oil day tank with volume of 100 cubic meters, storage diameter of 5.7 m, height of 5 m, dry weight of about 15 tons and total weight of 115 tons. The intensity of foundation shall be fully considered.
f. One sludge oil tank with volume of 100 cubic meters, storage diameter of 5.7 m, height of 5 m, dry weight of about 15 tons and total weight of 115 tons.
g. One lube oil storage with volume of 100 cubic meters, storage diameter of 5.7m, length of 5m and total weight of 115 tons.
h. One soft water storage with volume of 200 cubic meters and soft water equipment room.
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.
Notes: All above mentioned storages are not included in the offer.
3.2.2 Separator and fuel unloading station room
One separator and fuel unloading station room with length of 19m and width of 10m is built besides oil storage. Fuel unloading, transferring and purifying fuel will be carried out.
The following equipments are supplied for the power plant.
Four sets of separators with fuel treatment rate of 5T/h;
One set of heavy fuel oil unloading pump station with capacity of 58m3/h;
One set of heavy fuel oil transfer pump station with capacity of 25m3/h;
One set of diesel oil unloading pump station with capacity of 58m3/h;
One set of diesel oil transfer pump station with capacity of 25m3/h;
One set of sludge oil loading pump station with capacity of 25m3/h;
One set of lube oil unloading pump station with capacity of 10m3/h�?/DIV>
One set of lube oil transfer pump station with capacity of 10m3/h.
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