4.        System specifications:

4.1  DG system:

Rating of the D.G. set

Under above mentioned site conditions

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       Rating at       Alternator       Rating at

       engine         efficiency       alternator

       crankshaft                     terminal(MCR)

       KWm             ( % )        KWe         KVA(0.8 pf)

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Nominal        2206             94          2000       2500

Running   

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Note : COP rating will be 90 % of MCR

            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)

 

Rated power under ISO Conditions

Maximum continuous rating (MCR)    3000 HP

at engine crankshaft

Corresponding rotational speed        600  RPM

Under the following limiting ambient conditions :

Air temp. at turbocharger inlet              45 deg. C

Water temp. at charge air cooler inlet    32 deg. C

Deration to power applicable for engine       0 %(nil)

Beyond the abovementioned limiting conditions, deration to power as per ISO 3046 will be applicable.

Rated Power under site conditions mentioned above:                                         

Maximum continuous rating (MCR)     3000 HP

at engine crankshaft

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 %

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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.

 

Alternator

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

- Rated KVA                                               2500 KVA

- Power factor                                             0.8 lag

- Max. Alternator output at site                   2000 KW

- Duty                                                         Continuous

- Rated speed                                               600 RPM

- Output voltage                                         11000 V

- Efficiency at 100% load and 0.8 PF             94%

- Direction of rotation                                 clockwise

- Number of poles                                             10

- Rated frequency                                             50 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 Fuel Circuit system

4.3.1 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.

4.3.2 Oil storages

a.      Heavy fuel oil storages

The total heavy fuel oil storage capacity is dimensioned for 25 days of 80% power factor operation of all the engines.

Two 3000m3 tanks are designed for above ground installation.

 

b.      Heavy fuel oil buffer tank

The buffer tank is an intermediate tank for heavy fuel oil before the fuel goes to the separator unit.

The total heavy fuel oil buffer tank capacity is dimensioned for approximately 24 hours of full power operation of all the engines. The buffer tank ensures constant temperature and suction height for the fuel oil separators and thus it improves the fuel oil cleaning process.

One 300m3 HFO buffer tank is designed for above ground installation.

 

c.       Heavy fuel oil day tank

The total HFO day tank capacity is dimensioned for approximately 24 hours of full power operation of all the engines.

One 300m3 HFO day tank is designed for above ground installation.

 

d.      Heavy fuel oil unloading pump station

The function of the unloading pump unit is to pump fuel oil from tank trucks to the storage tank.

The unloading pumps and auxiliary equipment components are built on a steel frame, which forms a compact skid unit, and consists of the following equipments:

▲Two Electric motor driven unloading pumps with capacity of 58m3/h for each one;

▲Suction filter on pump suction side

▲Pressure gauges at outlet pipe

▲Local control panel for manual operation

▲Steel frame

▲Interconnection pipes, flanges, seals and valves

 

e.      Heavy fuel oil transfer pump station

The function of the transfer pump station is to pump heavy fuel oil from the storage tank to the buffer tank and to heat the fuel to a temperature of approximately 60°C. The transfer pumps and other components are built on a steel frame, which forms a compact skid unit, and consists of the following equipments:

▲Two electric motor driven transfer pumps with capacity of 25m3/h for each one;

▲Two single strainers on pump suction side

▲Pressure gauges at outlet pipe

▲Local control panel for manual operation

▲Steel frame

▲Interconnection pipes, flanges, seals and valves

 

f.        Heavy fuel oil separators

Centrifugal separators are installed to remove water and solids from the fuel. The separator unit receives fuel from the buffer tank and sends clean fuel to the day tank.

The following components are built on a steel frame, which forms a compact skid unit, and consists of the following equipments:

▲Four sets of separators with capacity of 5m3/h for each one;

▲Four separator delivery pumps;

▲Four single strainers on pump suction side

▲Four steam heaters for the heating of heavy fuel oil

▲One sludge tank

▲One sludge pump

▲One steel frame

▲One Local control panel for manual and automatic operation

�?nbsp;    One set of interconnection pipes, flanges, seals and valves

 

g.      Sludge oil tank

The sludge tank is used to store sludge consisting of oily and solid compounds with free and emulsified water separated from heavy fuel oil separators and lube oil separators.

One 100m3 sludge oil tank is designed for above ground installation.

 

h.      Sludge oil loading pump station

The purpose of the sludge loading pump station is to transfer the sludge from the sludge tank to a tank truck. The pump is specially designed for pumping sludge. The main components of the unit are:

▲One oily water pump with capacity of 10m/h;

▲One set of interconnecting pipes and equipment

▲One local control panel for manual operation

 

i.         Diesel oil storage

The total light fuel oil storage capacity is dimensioned for 5 days of full power operation of all the engines.

One 1000m3 tank is designed for above ground installation.

 

j.         Diesel oil unloading pump station

The function of diesel oil unloading pump station is to pump fuel oil from tank trucks to the storage tank.

The unloading pumps and auxiliary equipment components are built on a steel frame, which forms a compact skid unit, and consists of:

▲Two electric motor driven unloading pump with capacity of 58m3/h;

▲Suction filter on pump suction side

▲Pressure gauges at outlet pipe

▲Local control panel for manual operation

▲Steel frame

▲Interconnection pipes, flanges, seals and valves

 

k.       Diesel oil transfer pump station

The function of diesel oil transfer pump station is to pump fuel oil from the storage tank to the day tank.

The transfer pumps and other components are built on a steel frame, which forms a compact skid unit, consists of:

▲Two electric motor driven transfer pumps with capacity of 25m3/h;

▲Single strainer on pump suction side

▲Pressure gauges at inlet and outlet pipe

▲Steel frame

▲Local control panel for manual and automatic operation

▲Interconnection pipes and equipment

 

l.         Diesel oil day tank

The diesel oil day tank functions as an intermediate storage tank for fuel. The total DO day tank capacity is dimensioned for approximately 8 hours of full power operation of all the engines.

The 100m3 tank is designed for above ground installation.

 

m.     Viscosity control modules (booster)

Three viscosity control modules are designed for the power plant with capacity of 10m3/h, two work, one for standby, and consists 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;