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:

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

 

4.4  Lube oil circuit system

The lubricating oil system provides required lubrication for all moving parts on the engine. It consists of the engine related lubricating oil system which handles the cooling and filtration of the lubrication oil and the plant related lubricating oil system, with storage of new and old lubrication oil.

 

a.      Lube oil storage

The lube oil storage stores new oil for filling the engines. The 100m3 tank is designed for above ground installation

 

b.      Lube oil unloading pump station

The function of the lube oil unloading pump station is to pump new lube oil from tanker trucks to the lube oil storage. 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 pumps with capacity of 10m3/h for each one

▲Suction filters on pump suction side

▲Pressure gauges at inlet and outlet pipe

▲Steel frame

▲Local control panel for manual operation

▲Interconnection pipes, flanges, seals and valves

 

c.       Lube oil transfer pump station

The function of the lube oil transfer pump station is to pump lube oil from the storage tank to the lube oil service tanks. The transfer pumps and auxiliary equipment are built on a steel frame, to form a compact skid unit, and consists of:

▲Two electric motor driven transfer pumps with capacity of 10m3/h for each one

▲Suction filters on pump suction side

▲Pressure gauges at inlet and outlet pipe

▲Steel frame

▲Local control panel for manual operation

�?nbsp;    Interconnection pipes, flanges, seals and valves

 

d.      Lube oil service tank

The function of the lubricating oil service tank is to provide for intermediate storage of engine lubricating oil during maintenance of the engine.

The 16 m3 tank is designed for high position, and is installed in generator hall.

 

e.      Lube oil separator

One lube oil separator module with capacity of 2m/h is arranged for five generators, total in generator hall are five lube oil separator modules. Lube oil separator are used for cleaning lube oil and prolong usage time.

 

f. Lube oil tank

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.

The 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.

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 (optional)

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

Equipment delivered loose:

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

-      23 electric motor-driven lube oil-priming pumps

-      23 manual lube oil-priming pumps

-      23 lube oil coolers

-           23 centrifugal lube oil filters (FLL75 bypass type)

-           23 lube oil duplex type filters

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

 

4.5 Starting air circuit system

The DG is started by the compressed air.

Three air compressors and two air receivers are arranged for the power plant, the capacity of each air receiver is 4m3, which is enough for starting one generator 56 times without intermediate refilling of the receiver.

High-pressure compressed air about 3 Mpa from the air receivers will be sent to twenty-five generators through air main pipe.

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:

-      Three air compressors

-      Two air receivers

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

 

4.6 Cooling water circuit system

The engine cooling is achieved by open cooling water circuit.

Drawn by the water pump from the reservoir, 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 a cooling tower.

One cooling tower with cooling capacity to be 100m3/h is arranged for each generator, total twenty cooling towers for the power plant.

Equipment fitted on the engine:

-      One engine driven water pump

-            One lube oil cooler

-            One injector cooler

-      One water-cooled charge air cooler

Equipment delivered loose:

-          20 cooling towers

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

 

4.7 Intake air and ventilation system

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

For twenty diesel generators, air consumption is 312500m3/h. Twenty 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 20000m3/h; total airflow capacity is 400000m3/h.

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 10500 MJ/h. The air will be discharged through natural ventilation on the upper side of the main building.

 

4.8 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.

Four steam exhaust gas boilers are arranged for the power plant, each one will connect with five 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:

-          Twenty exhaust silencers

-          Four exhaust gas boilers

-          Insulation /lagging/cladding for exhaust ducting

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

 

4.9 Steam system

Four exhaust gas boilers are arranged for the power plant. Heat exchange area for each boiler is 112 m2, steam capacity for each boiler is 1000kg 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 stations, 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.

Drain trap is arranged on the end of steam pipe for equipment need to be heated.

Equipments for steam system:

-          Four exhaust gas boilers

-          One soft water supply unit

-          Steam distributors

-          One soft water storage (provided by client)

-          Insulation /lagging/cladding for steam pipes

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

 

4.10 Water treatment system

4.10.1 Raw water storage tank

The raw water storage tank provides water storage for raw water received from the local city water supply.The raw water storage tank has provisions for taking samples and adding chemicals for preventing biological growth.

The 200m3 tank is designed for above ground installation and provided by client.

 

4.10.2 Water treatment unit

The water treatment unit is designed for treatment of brackish water, with low organic matter and suspended solids content i.e. for typical well water. The treated water shall meet the requirements for boiler water.

Two water treatment equipments are installed for the power plant with capacity of 10m3/h for each one.

 

4.10.3 Treated water storage tank

The treated water is stored in the treated water storage tank before distribution to the consumers. The storage tank is made of corrosion proof material to prevent corrosion born particles entering the system.

The 30 m3 tank is designed for above ground installation.

 

4.11 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 meter 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.

 

4.12 Electrical system

4.12.1    H.V. system

Twenty 2MW/11kV/50HZ generators will work in parallel and supply electricity to two 11KV bus-bars, two 11kV bus-bars are connected with bus-bar linkage switchgear panel and isolation panel. The electricity from each bus-bar will be output with one main outgoing panel, total two outgoing panels.

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.

 

11kV generator system

Twenty 2MW/11kV diesel generators are arranged for generator station. 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 surge arrestors (standard delivery in China). As required by the buyer, four neutral connecting panels for earthing through one neutral resistor are supplied for the power plant. Each one connects with five generators. Only one generator can connect to the resistor by the knife switch during operation.

All twenty generators are connected with two bus-bars which are linked with busbar linkage panel. All 11kV H.V. panel adopt KYN28A 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. The 11kV busbar linkage panel adopt KYN28A metal-enclosed removable switchgears, the switch for busbar linkage panels adopts VS1 vacuum circuit breaker (with truck), its rated current is 1250A, and rated short-circuit breaking current is 31.5KA. The outgoing panels adopt KYN28A metal-enclosed removable switchgears, the switch for outgoing panels adopts VS1 vacuum circuit breaker (with truck), its rated current is 1600A, 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 LZZBJ9-11 200/5A 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-11 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

 

Busbar linkage panel

There are one busbar linkage panel and isolation panel.

Major Components in busbar linkage panel:

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 LZZBJ9-11 200/5A with two windings for each phase

PT type: one REL-11 with two windings for each phase

CT and PT are used for parallel operation.

3)      Digital integrated relay

DMR-301P digital integrated protection relay is adopted for output protection, and its protection parameter and function are configurable. The relay can indicate all parameters and store operation and accident record.

The following protection can be carried out on the relay:

-          Instant trip current

-          Over current

-          Over load

-          Single phase grounding

-          VCB ON/OFF indication

-          DSSX25 kWh and kVarh meter

-          Outgoing synchronous operate inspect

 

4.12.2    11kV transmission panel

The electricity will be output with three outgoing panels. All electrical equipment outside the outgoing panels will be not included in the offer.

One 1250kVA/11kV/400V station transformer is used for supplying 400V source for whole power plant.

 

4.12.3    L.V. system

The L.V. electrical systems consist of auxiliary electrical system for generator, common electrical system for power plant, lighting system, fire fighting system and maintenance system.

The auxiliary equipments for generator include twenty cooling towers (5KWx20), three air compressor motors (18.5kWx3), one DC power source panel (4kW), five lube oil separators (11kWx5), three boosters (18.5kWx3), and one boiler water supply unit (15kWx2).

The common equipments for power plant include HFO unload station (18.5KWx2), DO unloading pump station (18.5kWx2), HFO transfer pump station (11kWx2), DO transfer pump station (18.5kWx2), DO transfer pump station (11kWx2), Sludge oil loading pump station (11kWx2), HFO separator (18.5kWx4), Lube oil unloading pump station (11kWx2), Lube oil transfer pump station (11kWx2), Water treatment system (18.5kWx2) and oily water system (11kWx2).

The lighting and air conditioner system is about 100kW for each generator hall, 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).

 

4.12.3.1  L.V. power source for power plant

Two L.V. power sources are arranged for power plant. One is supplied with a station transformer (1250KVA/11kV/0.4kV). The second is supplied with an emergency diesel generator (400kW/0.4kV) when the whole power plant is stopped.

 

4.12.3.2   Emergency generator

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

 

4.12.3.3   DC panel

The power supply of control plant, protection, signal, automatic device and trouble lighting adopts 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 300Ah capacity for 24VDC output and 100Ah for 220VDC 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

 

4.12.4    Control system

4.12.4.1  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>