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Diesel Generator Proposal

Power Plant Proposal
Required Information for Power Plant Project design and quotation

Home > Equipments > HFO Diesel generator & Marine HFO Engine > 3x3.5mw MAN 8L 32/40 hfo diesel generator plant


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TECHNICAL SPECIFICATION
 
 
Power  Generation  Project
 
MAN 8L32/40
 

Contents


?/FONT> General

The proposed stationary 3 x 3.5MW diesel power generating plant is for base load application and intended for electricity production operation in parallel with public supply system.
The diesel engine is connected with the generator via flexible coupling. The fuel for DG sets can be either diesel oil or heavy fuel oil.
The mechanical auxiliary equipment of the DG will be grouped into functional modules to facilitate installation and operation.
Single bus design is used for its electrical design i.e. the power generated from 3 DG sets will be output to the bus. Power supply for the equipment in power plant itself will be taken from the bus through 11kV/0.4kV transformer. No additional standby generating sets are needed.

Main data of the power plant

The power plant mainly consists of 3 sets CHF3500/11000 diesel generating sets manufactured by Shaanxi Diesel Heavy Industry Co., Ltd. (SXD).
Rated power of each DG set under rated speed and ambient conditions:
- Electrical power (50/ 60Hz)                      3500kW
- Apparent power                                          4375kVA
-Power factor                            0.8
The DG set can output power efficiently under the following ambient conditions:
- Ambient temperature                               5-45?/DIV>
- Elevation                                                    ?000M
- Relative humidity                                    ?5%
- Water temperature at air cooler inlet      45?/DIV>
The DG sets can output rated power continuously and are capable of temporary 110% overload for 1 hour in every 12 operating hours under the following conditions:
Ambient temperature                                               25?/DIV>
Atmospheric pressure                                      100kPa
Cooling water temp. at air cooler inlet                25?/DIV>

Derating of DG output

The output and fuel oil consumption rate are to be corrected according to relevant technical documents of the diesel engine manufacturer when the service condition on site does not conform to the standard conditions specified in ISO3046-1995.
 
HT water and injector cooling water
Normal condition
Clear
PH
6.8--8
Total hardness (CaCO3 in ppm)
mg/l
max
100
Chlorinity
mg/kg
max
60
Total salinity
mg/kg
max
250
Density of acid ion ( SO2-4)
mg/kg
max
60
Fe
mg/kg
max
0.3
Silicon dioxide
mg/kg
max
50
Residue on evaporation
mg/kg
max
400
 
 
 
 
 
 
 
 

 

Quality of Light Fuel Oil (LFO)

Viscosity, min.
cSt at 40?/DIV>
2.8
Viscosity, max.
cSt at 40?/DIV>
14.0
Density, max. (at 15 °C)
g/ml
0.92
Conradson carbon res. max.
% mass
3.0
Sulphur, max.
% mass
2
Vanadium, max.
ppm
100
Sodium, max.
 
0
Ash, max.                                   
% mass
0.05
Water, max.                                  
% Vol
0.30
Water before engine, max.
% Vol
0.2
Flash point, closed Pensky-Martens, min.
?/DIV>
60
Pour point, upper max.
?/DIV>
6
Aluminum + silicon, max.   
mg/kg
25
Total sediment potential, max.
% mass
0.1
 
 
 
 
 
 

 

 

 

Quality of Heavy Fuel Oil (HFO)

 
 
Fuel oil specification
CIMAV 2003
A30
B30
D80
E/F180
G/H/380
H/k700
BS MA-100
 
M4
M5
M7
8/9
M9/-
ISO F-RM
A30
B30
E/F180
E/F180
G/H/K380
H/K700
Fuel-system related characteristic values
Viscosity(at 50?
mm2/s(cSt)
max.
40
40
80
180
380
700
Viscosity(at 100?
 
max.
10
10
15
25
35
55
Density(at 15?
g/ml
max.
0.975
0.981
0.985
0.991/1.010
Flash point
?/DIV>
min.
60
Pour point(summer)
max.
6
24
30
Pour point(winter)
max.
0
24
30
Engine-related characteristic values
Carbon residues(Conradon)
% wt.
max.
10
10/14
14
15/20
18/22
22
Sulfur
3.5
3.5
4
5
Ash
0.10
0.15
0.20
Vanadium
mg/kg
150
150/300
350
200/500
300/600
600
Water
% vol.
0.5
 
0.8
1
Sediment(potential)
% wt.
0.1
Supplementary characteristic values
Aluminum and silicon
mg/kg
max.
 
 
 
 
 
 
Asphalts
% wt.
 
 
 
 
 
 
Sodium
mg/kg
 
 
 
 
 
 
Cetance number of low-viscosity constituent minimum 35
Fuel free of admixtures not based on mineral oil, such as coal oils or vegetable oils; free of tar oil and lubricating oil(used oil)

 

 

 

 

 

 

 

 

 

Lube oil characteristics

Lube 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 standards

The 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 layout

This 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 building

The main DG building consists of three rooms i.e. switching room, DG room and auxiliary room.

DG room

The 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 room

The 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 room

Switching 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 station

A 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 area

Fuel 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 station

Heavy 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 set

CHF3500/11000 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 set

Type                                                        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 engine

12V32/40 engine is a four stroke, single action, direct injection, gas turbocharging, intercooler medium speed high power diesel engine.
Type
8L32/40
Model
4 stroke, V-type, direct injection, gas turbocharging, air intercooled
 
N0. of cylinders       
8
Rotating direction
clockwise (view from PTO)
Cylinder bore 
 
320 mm
Stroke    
400 mm
Swept volume 
 
32.17 dm3
Compression ratio 
14.5/1
Type of combustion chamber
direct injection
Injection method
mechanical drive, single body injection pump
Starting method
compressed air starting
Max. continuous rating (MCR)
4000kW
Overload power (1h out of 12 h)
4400kW
Rated speed
750 r/min
Mean effective pressure
2.49MPa
Max. explosion pressure      
19.0±0.29MPa
Min. stable speed 
250 r/min
Firing speed  
80 r/min
Exhaust temp. at cyl. outlet
510±50?(difference between any two cylinders ?0?
Fuel oil consumption    
185+5? g/kw.h (Lev= 42700kj/kg?/DIV>
Lube oil consumption          
?.0 g/kw.h
External dimension             
7,270 x 2,635 x 4,170 mm(L×W×H?/DIV>
Weight (dry)  
47 ton

Main data of generator

Type                                                        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 set

Steady 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 system

The 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 system

The 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 system

Diesel 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  sets

The 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 sets

The 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 unit

It 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 system

DG 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 set

The 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  sets

The 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/Plant

For 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 system

For 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 system                                        

Engine 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/DG

HT 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/DG

Main 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/Plant

The 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/DG

Air 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 system

The 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

No.
Designation
Quantity
1
Local control panel
3
2
Generator control cubicle
3
3
PT cubicle
3
4
CT cubicle
3
5
Generator outgoing switch cubicle
3
6
Neutral earthing cubicle
3
7
Generator protection cubicle
3
8
DC24V panel
2
9
DC110V panel
2
10
Common pump control panel
1
12
0.4KV control cubicle
1
13
0.4KV switch cubicle
1
14
Factory power control cubicles
1
15
0.4KV compensation panel
1
16
Transformer 11KV/0.4KV 1250KVA
1
17
0.4KV outgoing cubicles
1
18
Transformer incoming switchgear cubicle
1
19
Busbar PT cubicle
1
20
11KV outgoing cubicle
1
 

- 2x1.5mva containerized MAN HFO diesel generator sets 10/6 2014
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Total 1 pages 3 items, Now at 1 page. First. Last. Next End


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