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Quality of Light Fuel Oil (LFO)
Quality of Heavy Fuel Oil (HFO)
Lube oil characteristicsLube oil for engine lubrication and rockerarm lubrication:
Viscosity: SAE40
Total base number (TBN): �?0
Please consult recommended lube oil specifications of the engine manufacturer for specific lube oil to be used.
Lube oil for governor and turbocharger:
HU45(GB2537-81)
Codes and standardsThe plant will be designed and manufactured according the following codes and standards.
Mechanical system: Relevant ISO and GB standards
Electrical system: IEC standards.
�?/FONT>. General layoutThis 3 x3.5 MW diesel power generating plant will occupy an area dividing into four sections i.e. main DG building, cooling water station, tank area and heavy fuel treatment station.
Main DG buildingThe main DG building consists of three rooms i.e. switching room, DG room and auxiliary room.
DG roomThe elevation of the DG room is approx. 16m equipped with a 7 ton bridge crane for maintenance and lifting of components. 6 DG sets are laid out in parallel transversally.
Auxiliary roomThe auxiliary room is on the engine side of the DG room . Auxiliary equipment such as oil pumps, water pumps, heat exchangers, air compressors, air bottles and some pipes will be installed in the room and the air intake and gas exhaust pipes as well as HT water expansion tank will be installed at the top of the room.
Switching roomSwitching room is located at the generator side of the DG room. There are specific rooms for high voltage, central control, switching gear and transformer.
Cooling water stationA fresh water pond will be build in the Plant. Low temperature water circulating pump, central plate heat exchanger and LT water circulating pump. Plant water treatment facilities are located in the water treatment room. There is a water pump room for distinguish pump and pumps for daily life and production.
Tank areaFuel oil storage tanks in the tank area will be built together comprising two or three 1,000m3 fuel oil storage tanks and eight 40m3 light diesel oil service tank. The capacity of the fuel oil tanks can enable the operating of 3 DG sets for days.
Position for slag oil is reserved in the tank area. Transfer pumps for light diesel oil and heavy fuel oil will be installed inside the tank area.
Heavy fuel oil treatment stationHeavy fuel oil separating unit is located in the station. The unit consists of 1centrifugal separators and feed pump, strainer and heater. Its function is to separate water content and particles in the heavy fuel oil which are hazardous to engine.
�?/FONT>. Diesel generating setCHF3500/11000 DG set consists of one set of MAN 8L32 / 40 diesel engine as prime mover, one generator, excitation system and AVR, control and monitoring system, protection system and various auxiliary equipment. The diesel engine and the generator will be installed on the common base and connected through flexible coupling. The DG set features reliable running, prolonged TBO and easy maintenance.
Specification of DG setType CHF3500/11000
Rated power 35000 kW
Rated voltage 11kV
Rated current 230A
Number of pole pairs 4
Power factor 0.8 (lagging)
Rated frequency 50 Hz
Rated speed 750 r/min
Phase 3 phase
Excitation brushless excitation
Dry Weight 77ton
※External dimension(L×W×H) 10,875 x 2,710 x 5,120 mm
�?The dimensions and weight may vary depending on the generator make and type.
Main data of diesel engine12V32/40 engine is a four stroke, single action, direct injection, gas turbocharging, intercooler medium speed high power diesel engine.
Main data of generatorType TFW3500-8/1730
Rated power 3500kW
Rated voltage 11kV
Rated speed 750 r/min
Rated frequency 50Hz
Power factor 0.8 (lagging)
Efficiency 96%
Insulation Class F
Protection IP23
Cooling method Air cooling
Excitation Brushless excitation
Lubricating method Complex lubricating
Bearing lube oil N46 (GB443-89)
Weight
External dimension
Performance of DG setSteady state voltage deviation ±2.5%
Transient voltage regulation within +20%- -15%
Voltage recovery time �?.5 second
Voltage fluctuation �?%
No-load voltage setting range 95% --105% rated voltage
The distortion rate of sinusoidal waveform
of line voltage at no-load rated voltage. �?%
Steady state frequency deviation 5%
Transient frequency deviation ±10%
Frequency recovery time 7 second
Frequency fluctuation �?%
�?/FONT> Mechanical auxiliary systemThe proper function of the DG-set is dependent on the mechanical auxiliary systems. The proposed systems have been optimized for the this particular plant. The function of the systems are to provide the engine with fuel, lubricating oil, starting air, cooling water and charge air at required quantity and quality as well as to dispose of exhaust gases in a proper manner.
Fuel oil systemThe main function of the fuel oil system is to supply the Diesel engine with fuel oil of the necessary amount, pressure, temperature, viscosity and quality during all loads and environmental conditions.. The power plant is using Heavy Fuel Oil as the main fuel.
1. Fuel oil storage systemDiesel oil transfer pumps are to be equipped to facilitate unloading of fuel oils. The diesel oil transfer pump is for delivering diesel oil to the diesel oil daily tank for starting ,running and stop operations of the DG sets.
Main facilities in the fuel oil storage system are
Strainer 8 sets
LFO transfer pump 4 sets
LFO delivery pump 2 sets
LFO daily tank 8 set
LFO storage tank 2 sets
Light fuel oil daily tanks are all equipped with level indicator and level switches for alarm and control.
2. FO feeding unit 3 setsThe function of the feeding pump unit is to pump fuel oil from the storage tank to the day tank. It provides the engine with filtered fuel of correct quantity and pressure. It consists of feeding pump, fine filter, flow meter, booster pump, and control system. Its function is to supply fuel oil to diesel engine at an appropriate viscosity, pressure, flow and cleanness. Transfer pumps and other components are built on a steel frame, which forms one compact unit. Every two DG sets share one unit
Main facilities are as follows:
Electric feeding pump 2 sets
Electric booster pump 2 sets
Duplex strainer 2 sets
Duplex fine filter 1 set
Pressure drop indication and alarm 1 set
Control panel 1 set
Connecting pipe, valve, flanges 1 set
Steel base frame , ; 1 set
3. Heavy fuel oil separating unit 1 setsThe unit consists of 2 centrifugal separators and feed pump, strainer and heater. Its function is to separate water content and particles in the heavy fuel oil which are hazardous to engine.
Its working procedure is as follows:
First heat up the HFO coming from HFO storage tank to a temperature suitable for separation.
Then separate the HFO according to its nature through appropriate , , gravity disk.
HFO after the treatment will be delivered to HFO daily tank. The slag a, nd contaminate, d water will be drained to slag collector. Switch on the slag oil pump to drain it to slag oil tank when the slag in the collector accumulates to certain amount.
4. HFO feeding unitIt consists of feeding pump, fine filter, flow meter, blending device, booster pump, heater and viscosity-temperature control system. Its function is to supply fuel oil to diesel engine at an appropriate viscosity, pressure, flow and cleanness and realize the switch over between diesel oil and HFO. Every two DG sets share one unit.
Its working procedure is as follows:
Measure the temperature and viscosity of the HFO coming from HFO daily tank through thermal transmitter and viscometer. Heat up the HFO automatically to the set temperature, at which the viscosity of HFO can ensure the normal operation of the diesel engine. Finally feed the HFO after fine filtration to DG sets though the booster pump.
Main facilities are as follows:
Electric feeding pump 2 sets
Electric booster pump 2 sets
Degas blending tank 1 set
Duplex strainer 2 sets
Fuel oil heater 1 set
Temperature-viscosity control device 1 set
Duplex fine filter 1 set
Pressure drop indication and alarm 1 set
Control panel 1 set
Connecting pipe, valve, flanges 1 set
Steel base frame 1 set
Lube oil systemDG lubricating system consists of diesel engine lubricating system and generator lubricating system. The diesel engine lubricating system includes main lube oil circuit, rockerarm lubricating circuit and turbocharger self lubricating system.
1. Main lube oil circuit of diesel engine 1 set/DG setThe main lube oil system of the diesel engine is to supply lube oil for moving parts of the engine. Main lube oil pump delivers lube oil from lube oil tank to engine inlet through lube oil fine filter. Lube oil cooler and three-way thermostatic valve ensure the temperature of the lube oil at engine inlet.
Main facilities are as listed below:
Electric lube oil delivery pump 2 sets
Lube oil cooler 1 set
Lube oil fine filter 1 set
Thermostatic valve 1 set
Control panel 1 set
Connecting pipes, valves, flanges 1 set
Steel base frame 1 set
2. Lube oil separating unit 3 setsThe function of lube oil separating unit is to separate the water content and particles in the main lubricating system at fixed intervals. Two DG sets share one unit. Lube oil of two DG sets can be separated during operation of DG sets.
Each lube oil separating unit consists of the following facilities:
Lube oil separator 2 sets
Filter 2 sets
Heater 2 sets
Slag oil tank 1 set
Control panel 1 set
Connecting pipe, valve, flange 1 set
Steel base frame 1 set
3. Lube oil storage system 1 set/PlantFor storage, compensation and refill of lube oil for the Plant.
Lube oil storage tank 1 set
Lube oil delivery pump 1 set
Engine circulating lube oil tank 1 set
Waste oil tank 1 set
4. Emergency lube oil systemFor supplying necessary lube oil for stop of engine when accidents such as loss of power, faulty lube oil pump etc.
Main facilities:
Gravity oil tank 8 sets
Automatic oil feeding device 8 sets
Cooling water systemEngine cooling water system comprises three portions i.e. high temperature water circuit, low temperature water circuit and injector cooling circuit. LT water is cooled by cooling tower. HT water and injector cooling water are cooled by LT water through heat exchangers.
1. LT water circulating system 1 set/Plant
LT water circulating system consists of pump station and cooling tower. Its function is to cool air cooler, lube oil cooler, HT water cooler and injector cooler.
Main facilities are as follows:
LT circulating pump 6 sets
Cooling tower 6 sets
2. HT water system 1 set/DGHT water system is to cool cylinder liners, cylinder heads and turbocharger consisting of cooling unit and expansion tank.
Main facilities included in the cooling unit are:
HT water pump 2 sets
HT water cooler 1 set
Thermostatic valve 1 set
Control panel 1 set
Connecting pipe, valve, flange 1 set
Steel base frame 1 set
3. Injector cooling water system 1 set/DGMain facilities are:
Injector cooling water pump 2 set
Injector cooler 1 set
Thermostatic valve 1 set
Cooling water tank 1 set
Control panel 1 set
Connecting pipe, valve, flange 1 set
Steel base frame 1 set
Compressed air system 1 set/PlantThe compressed air system is to supply compressed air for engine starting. Air cooled air compressor produces compressed air and the air will be stored in the starting air bottle and low pressure control air bottle. The capacity of the starting air bottle shall enable 12 times starting of the 2 DG sets.
Main facilities included are:
Air compressing unit 2 set automatic start/stop
Starting air bottle 4 sets
Control air bottle 4 set
Relief valve 4 set
Control air treatment device 4 set
Local air control panel 1 sets
Air intake/Gas exhaust system 1 set/DGAir intake/gas exhaust system consists of air filter, air intake pipe, turbocharger, air cooler, air manifold, exhaust gas manifold, gas boiler and silencer.
The air outside the building enters into the turbocharger through air duct after filtration of the air filter. The high temperature air after supercharging is cooled by the air cooler and enters into cylinders for combustion through air pipes. The high temperature gas with high pressure after combustion enters into turbocharger through exhaust gas pipes and pushes the turbocharger to rotate and in the meantime drives air compressor for supercharging. The exhaust gas is divided into two routes, one is emitted into open air through silencer, the other goes to the gas boiler to produce steam. The flow of exhaust gas in each route can be regulated through valve.
Exhaust silencer 1 set
Air filter 1sets
Exhaust pipe expansion joint 1sets
Exhaust manifold expansion joint 1 sets
Air intake pipe expansion joint 1sets
�?/FONT>. Electrical control systemThe outgoing of 2 DG sets connected to the 11KV bus, which is single bus. The frequency of the local power grid is50/ 60Hz. The short circuit current of single DG set is 2.69kA. The max short circuit current of 11kV bus is 16.4kA. The 11kV circuit-breaker is indoor vacuum circuit-breaker, whose rated current is 20kA. The 11kV switchgear is indoor fixed switch cubicle.
The factory power is taken from 11kV bus via factory transformer to lower the voltage down to 0.4KV and connected to switchgear which supplies power to auxiliaries control system and for workshop lighting , ventilation, security and common equipment.
The 2 DG sets have an integrated control system, which performs the control, protection, monitoring functions of the DG sets.
Electrical equipment
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