-      High-pressure pipe connection for each cylinder

    Equipment delivered loose:

    1)     One HFO separator double module

    2)     One fuel viscosity control module (booster) consisting 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;

    3)   Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses, supports, etc as necessary up to Daily Tank.

    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

    The heavy fuel oil from daily HFO tank and diesel oil from daily DO tank will be pumped to the mixing vessel on the booster module through two fuel feed pumps. After heated by steam, the heavy fuel oil (or diesel oil) with constant viscosity about 12-15 cst will be pumped to fuel main pipe. The booster module is used for controlling viscosity and supplying fuel for generators. Fuel-supplying capacity for the booster module is 2500 kilograms one hour (Maximum feed capacity is 5000kg one hour, return oil is 2500kg one hour). Return oil from each generator will back to the mixing vessel through return main pipe.

    Fuel change between HFO and DO can be achieved through the 3-way valve on booster module, but this kind of fuel change is suitable for five generator at the same time.

    For changing fuel on one individual generator, two DO change gear pumps are installed in the booster. Start one of the two pumps, open the DO valve and close the HFO valve on changeover oil tank beside the generator, fuel for the generator will be changed to diesel oil.

    4.4  Lube oil circuit system

    Oil sump capacity (ltr)

    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 & also increases the time between oil changes by lube oil separator module. Two lube oil separator modules are supplied for the power plant, each one for two generators.

    The total oil capacity of this lube oil tank is 2000 liters. 

    Lube oil consumption

    The average lube oil consumption is 1.6 g/kWh (+/- 0.2 g/kWh) at MCR at crankshaft for a well-run engine.

    Two lube oil separator modules are supplied for the power plant, one for three generators, and another for two generators. Lube oil separator is used for cleaning lube oil and prolong usage time.

    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 (option)

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

    Equipment delivered loose:

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

    -       Four electric motor-driven lube oil-priming pumps

    -       Four manual lube oil-priming pumps

    -       Four lube oil coolers

    -       Four centrifugal lube oil filters (FLL75 bypass type)

    -       Four lube oil duplex type filters

    -       Two lube oil separator modules

    -       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.

    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

    -      Four air bottles of 500 ltrs (30 bar) capacity. This capacity is enough to start the engine 7 times without intermediate refilling of the receiver.

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

    4.6 Cooling water circuit system

    The engine cooling is achieved by open cooling water circuit.

    Drawn by an engine driven water pump from the reservoir, the raw 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 returns to the cooling tower.

    One cooling tower with cooling capacity to be 100m3/h is arranged for each generator, total four cooling towers for whole 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:

    -      Four cooling towers (civil construction provided by the buyer)

    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 four diesel generators, air consumption is 50000m3/h. Four axial-flow explosion-proof fans opposite to each generator shall be arranged for the main building on the engine side.

   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 1680 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 VI of the international Convention for the Prevention of Pollution from ships, 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 VI): 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.

    Two steam exhaust gas boilers are arranged for the power plant. 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:

    -     Four exhaust silencers

    -     Two 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

    Two exhaust gas boilers are arranged on the roof of control room. Heat exchange area for each boiler is 67 m2, steam capacity for each boiler is 700kg one hour at 170 degree centigrade and 0.7 Mpa. Steam from boilers will flow to steam main pipe and divide to separator, booster 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, condensation water will be not recycled.

    Equipments for steam system:

    -     2 exhaust gas boilers

    -     4 water feed pumps

    -     3 Steam distributors

    -     Insulation /lagging/cladding for steam pipes

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

    4.10 Water soften system for exhaust gas boiler

    One water soften equipment (double module) is arranged for the power plant, water treatment capacity is 2000kg one hour.

    The water soften equipment adopts resin exchanger treatment system.

    Equipments for water soften system:

    -     One water soften equipment (double module)

    -     Two water feed pump

    -     One water tank

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

    4.11 Electrical system

        4.11.1 H.V. system

        Four 2MW/6kV HFO generators will work in parallel, supply electricity to one 6KV bus-bar.

        6kV generator system

        Four 2MW/6kV diesel generators are arranged for the power plant. 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, one added neutral panel for earthing through one neutral resistor is supplied for the power plant. Only one generator can connect to the resistor by the knife switch during operation.

        All four generators are connected with a single bus-bar. One 6kV bus-bar PT panel is arranged for parallel operation. All 6kV H.V. panel adopt KYN28A-12 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 generator bus-bar connects to one outgoing panel. The switch adopts VS1 vacuum circuit breaker (with truck), its rated current is 3000A, and rated short-circuit breaking current is 40KA.

    Generator switchgear

    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 LZZBJ9-6 0.5/10P 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-6  6kV/�?. 0.1 kV /�?/SPAN>3. 0.1 kV /�?/SPAN>3 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:

    6kV outgoing panel

    Major Components in switchgear:

    1)      3 pole truck type DC/AC 220V electrically operated motor energized VS1 Vacuum Circuit Breaker.

    2)      Metering / Protection CT

    CT type: CT LZZBJ9-6 3000/5A with two windings for each phase

    One group for current difference protecting between transformer’s input and output; one for current protection and power measuring.

    3)      Digital integrated relay

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

    The following protection can be carried out on the relay:

    -      Differential current

    -      Instant trip current

    -      Over current

    -      Over load

    -      Gas

    -      High Insulation oil temperature

    -      High Insulation oil pressure

    4)      Local / Remote control selector

    5)      VCB ON/OFF indication

    6)      DSSX25 kWh and kVarh meter

    6kV Incoming panel for station transformer

    Major Components in switchgear:

    1)      3 pole truck type DC/AC 220V electrically operated motor energized VS1 Vacuum Circuit Breaker.

    2)      Metering / Protection CT

    CT type: CT LZZBJ9-6 100/5A with two windings for each phase

    3)      Digital integrated relay

    DMR-301 digital integrated protection relay is adopted for protection, and its protection parameter and function are configurable.

    The following protection can be carried out on the relay:

    -       Differential current

    -       Instant trip current

    -       Over current

    -       Over load

    4)     VCB ON/OFF indication

    5)     DSSX25 kWh and kVarh meter

    6)     Fixed PT installation truck with arrester.

    PT type: one REL-6  6kV/�?/SPAN>3. 0.1kV/�?/SPAN>3. 0.1kV/�?/SPAN>3 with two windings for each phase

    One group of winding in potential transformers is star connected for measuring and protection system. Another group of winding is triangularly connected for single phase earthing protection.

        4.11.2    L.V. system

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

        The auxiliary equipments for generator include 4 cooling towers (5KWx4), 3 air compressor motors (5.5kWx3), 2 lube oil separator motors (2.2kWx2), 1 boosters (17kWx1) and one DC power source panel (4kW).

        The auxiliary equipments for power plant include 2 HFO pump motors (18.5KWx2), 2 DO pump motors (18.5KWx2), 1 HFO separator module (22kW), 4 boiler water feed pump motors (2.2kWx4) and one soft water pump motor (3kW).

        The lighting and air conditioner system is about 30kW, 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).

        4.11.2.1 L.V. power source for power plant

        The electricity for the power plant is supplied by a 250KVA transformer from the 6kV bus-bar.

        4.11.2.2 DC panel

        The power supply of control plant, protection, signal, automatic device and trouble lighting adopts 220VDC/30AH and 24VDC/60AHdirect 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 60AH capacity for 24V 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

        Protections provided for Chargers

        6)       Over load / short circuit / earth fault

        7)       Over voltage

        4.11.3    Control system

        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 260V

        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°C

        Reactive sharing      Auto regulating

        8)     T4500 auto synchronizer

        SELCO T4500 auto synchronizer is designed for automatic synchronization between generator and bus-bar in a minimum of time by controlling the speed via the electric servomotor on the governor.

        The T4500 measures the voltage across two phases on either side of the circuit breaker in order to obtain data on voltage, frequency and phase difference for closing the circuit breaker at exact phase accordance.

        The synchronization function will become active when the difference between the bus voltage and the generator voltage is within limits. The voltage difference is selectable between 2% to 10%.

        When the synchronization function is active, the T4500 will automatically adjust the speed of the generator through the governor in order to match the frequency to the bus-bar.

        The T4500 will continuously adjust the generator speed until the frequency difference is within limits. When the voltage and frequency difference are within limits, the closing signal will be activated just before the next phase accordance, anticipating the circuit breaker make time. The T4500 compensates for this make time so that the circuit breaker will close exactly at zero phase.

        Specifications for the T4500:

        Circuit breaker operating time               20~200mS

        Frequency difference                       0.1~1Hz

        Voltage difference                         10%

        Reference voltage                         110/100V with voltage matching

        Operating Temp                           -20~+70°C

        Contact rating , ;                             AC: 440V, 2A, 250VA; DC: 110V, 2A, 100W