Technical parameter for Generator Sets
Type	7H32/40
Brand	ZGPT-HYUNDAI
Dimension (L×W×H)  mm	9486×2810×4130
Weight               t	78
MCR           kW	3209
Voltage Rating          kV	11
PF	0.8
Rated Speed           rpm	750
Output Frequency            Hz	50
Steady-state voltage adjustment rate   %	±0.5
Voltage fluctuation rate          %	<.5
Frequency fluctuation rate      %	<5
Load mutation frequency settling time (S)	<3
Mutation load voltage stabilization time (S)	<2
Terminal connection	3phase,3wire
Fuel type	Diesel fuel oil or HFO
Engine
Type	7H32/40
Brand	HYUNDAI
MCR             kW	3325
Cylinders	7 L
Spec. fuel oil consumption   g/kWh	181
Spec. lub oil consumption    g/kWh	0.7
Starting system	Compressed Air
Cooling system	Water cooling
Rated Speed            rmp	750
Mean eff. pressure (MEP)         bar	24.9
Piston speed             m/s	10
Displacement /cylinder              L	32.2
Governor style	Electronic governor
Exhaust gas temperature (after TC)           oC	345
Exhaust back pressure(Max)       mbar	30
Compression ratio	15:1
Stroke               mm	400
Bore               mm	320
Alternator
Brand	Leroy Somer/ ABB/ Siemens/AVK /HYUNDAI
MCR                  kW	3209
Voltage Rating           kV	11
Rated Frequency          Hz	50
PF	0.8(Lag)
Field System	Brushless, PMG-excited
Insulation Grade	H
Grade of Protection	IP23
rated speed           rpm	750
Exotherm  Stator / Rotor　�	F/F
Coolant method	Self-fan coolant

1.      Company introduction

Zhejiang Zhonggao Power Technology Co., LTD. (short for ZGPT), with headquarter in Zhejiang, China, has two production bases in Yiwu and Hangzhou, founded in 1995.

ZGPT is specialized in the research and development, manufacturer, sales, service, establishment of power plant, investment and EPC of middle and high-end diesel generators at home and abroad and HFO main engine for power plant as well as auxiliary equipment. ZGPT shall also provide the whole power system solutions to customers, push forward the demands of power at home and abroad and strive for the honoured enterprise of China and the world.

In recent years, the development pace of ZGPT has been accelerated ceaselessly. In 2004, ZGPT, cooperated with Zhejiang University to set up Zhejiang University-ZGPT technology joint research and development centers,  is specialized in the research about environmental protection and energy conservation of diesel generator set, and achieved many patents of parallel operation, energy conservation and vertical control cabinet of diesel generator set, so as to ensure the leading technology and high quality. Meanwhile, with regards to own special experience and technology, ZGPT has published the first professional textbook of Diesel Generator set that has been adopted by many domestic colleges and universities.

The normative management plays an important part in the core competence of enterprises. ZGPT learns from the "2+1" mode of management (that is, Status manuals, operating instructions + support platform) to implement the normative management to ensure every post and works having a dependable base. Meanwhile,   ZGPT has also learned from the Haier OEC management from the target management system to ensure the continuous improvement for all employees. In 2008, ZGPT took the lead in introducing ERP (Enterprise Resource Planning) system so as to increase the response speed and ability of technical response, technical proposal, manufacturing control delivery time control, cost management, etc.

Quality is the survival of an enterprise. ZGPT has established perfect quality management system and passed ISO9001 quality certificate and ISO14001 environmental management certificate.  ZGPT passed Quality Inspection Certificate in 2005, and achieved Certificate of Conformity of Quality System Certification of Military Products and McIntyre Certification of State Information Department in 2006,  rated as Zhejiang Medium-Size High-tech Enterprise by Chinese Academy of Sciences.

ZGPT always looks upon our clients as God. ZGPT not only provides the satisfactory products to customers, but also proposes "5S" standard services, that is, on the one hand, absorbed the service workers, on the other hand, organized the communications between customers and internal technicians and service workers, also organized the training to enhance the ability and quality of service workers. ZGPT strives for the first generator set of China brand by quick responses to customers and provision of quick and satisfied services to customers.

ZGPT has won the acclaim of the professionals in these fields and established a good corporate reputation by strong technical strength, reliable quality, favorable pre-sales and after-sales service, timely delivery and complete service networks, having achieved impressive performances in power plant, data base, electricity, oil field, telecommunication, smelting industry, civil aviation, bank, supermarkets, etc. 

2.      General rules

1.1 This technical program applies to Iraq 12MW Power station, which put forward the technical requirements of equipment for HFO power plant, and the design, structure, performance, installation as well as delivery for auxiliary equipment.

1.2 The basic requirement of technical performance, technical parameter, scope of supply, technical service as well as responsibility are all provided in this technical program.

1.3 Our company is responsible for supply with completely new, advanced, reliable, and integrate equipment with rational combination which has achieved or surpassed national standard.

1.4 Civil construction is not involved in the scope

3.      Codes ,standards , units and language

Equipment, parts and auxiliary equipment, provided by the sealer, correspond with the latest version of the standard, but they are not limited to the following standard:

3.1 State Standards

-GB Relevant Standards

-ISO Standards

-IEC : International Electro-technical Commission

-KS : Korean Standards

-JIS : Japanese Industrial Standards

-ZGPT Factory Standard

3.2 Units and language

In all correspondences of technical documents, schedules and drawings, metric units of all measurements shall be used.

The English language shall be used in all documents, drawings, name plates and correspondences between contractor and client.

4.      Design parameter

4.1 Standard environmental conditions

Refer to ISO 30461/1-2002, the standard environmental condition:

Site Altitude (barometric pressure)         0 m

Environmental temperature:              25^oC

Barometric pressure:                    1bar

RH (relative humidity):                  30%

Air temperature before T/C blower inlet    25^oC

4.2 Local environmental conditions

Site Altitude (barometric pressure)        150m

Maximum ambient temperature           50^oC

Minimum ambient temperature             -10^oC

Average maximum ambient temperature    Not quite clear

Average minimum ambient temperature     Not quite clear

Average wind speed                    Not quite clear

Average annual rainfall                 Not quite clear

Relative humidity                     10%

4.3 Fuel Specification

For a main fuel of the power plant is heavy oil. Light diesel oil for a start-up, stop and maintenance.

The heavy fuel oil shall have the viscosity characteristics that the viscosity must be within the range of 12 ~ 18 cSt with the heating lower than 150 Deg.C.

The viscosity of Diesel oil shall be of 2.0 ~ 14 cSt at Engine inlet under the power plant operating conditions.

Heavy fuel oil specification:

_specific weight at 16.5 deg.c (0.95)

_Flashing point min at 56deg.c

_Viscosity 120 sent. stoc. at 50 deg.c

_Flow point Max + 21 deg.c

_percentage(S)quantity is 3.5%

_Percentage(C) is 6.5% after burning

_Water containing &(volume percent) residual 1.5%

_Thermal value (11500) kcal/kg

4.4 Lubrication oil Specification

The lubricating oil for engine shall be selected from the list of recommended lubricating oils for engine, which shall be of HD (Heavy duty) API-CD class and SAE 40.

4.5 Cooling water for diesel engine

The cooling water system is designed for using normal fresh water with corrosion inhibitor, in order to prevent incrustation and corrosion attack.

The following water quality shall be valid;

For engine

-  PH values  :                   7~9

-  Total hardness as CaCO3:       Max. 75 ppm (mg/liter)

-  Chloride as CI   :              Max. 80ppm (mg/liter)

-  Sulphate content      :          Max. 100 ppm (mg/liter)

-  Silicate as SiO :              Max. 60 ppm (mg/liter)    

-  Residue after evaporation       :      Max. 400 ppm (mg/liter)   

5.      Customer Requirements

Power station site: Iraq

Total capacity of power station: 12MW

Voltage: 11kV 

Frequency: 50Hz      

PF (Power Factor): 0.8pf 

6.      Summary of 12MW power station

6.1 Overall description of power station

There are 4 sets ZGPT- HYUNDAI 7H32/40 diesel generating sets in 12MW heavy oil power station, each set rated power: 3209KW. Excluding site degradation and Plant utility power consumption,, the total net output of power station is about 12 MW in continuous operation. Voltage: 11kV, Frequency: 50Hz, PF: 0.8pf, Speed: 750rpm.

The design picture of standard electrical station:

12MW power station contains engine hall, exhaust system and exhaust boiler, radiated coolant system,fuel depot, pump station, maintenance workshop & warehouse and working building. Generating sets, auxiliary machines, supply unit, lube filtration separator and control system are all installed in power station. While the actual station design could be adjusted by weather, environment and terrain, but principle of proximity should be considered to prevent too much a long pipe arrangement. At the same time, the heat of heavy fuel oil tank is realized through the vapor of exhaust boiler, so the short line is in favor of heat insulation.

The heavy fuel oil could be the main fuel and light diesel oil the auxiliary fuel. With the main generating sets parallel operation, each unit can input or exit operation. The control system could adjust power balance, power of different sets, which has protective measures of inverse power, over current, etc.

(Suggestions)The power station need to collocate a 250kVA auxiliary engine, which can supply the black start power, light fuel oil, 24V storage battery start, power -0.4kV, frequency-50Hz, PF-0.8pf, and rotated speed-1500rpm. When the power station comes into good running, the auxiliary engine turns to the emergency standby sets.

Transformer, collocate by power station, provide the main auxiliary equipment with working power supply, the electricity of station lighting and domestic consumption.

6.2 Characteristics of heavy oil power station

(1) Highly-structured corollary equipment, flexible installation site and short construction period

The corollary equipment of heavy fuel oil generating sets is rather simple for little corollary equipment, small volume and light in weight. Compared with water turbine-generator set needed to dam, vapor generating set needed to boiler, fuel storage, and water treatment system, the diesel generating set has advantages of small occupation, high construction speed and low invest cost.

Modularity unit system used for heavy fuel oil generating sets, flexible arrangement according to the terrain, which is fit for construction of mountain area and mine area, subjected to small regional terrain restrictions.

(2) High thermal efficiency, low fuel oil consumption and low operation cost

The heavy fuel oil machine extended from diesel is the highest thermal motors of thermal efficiency, of  which the effective thermal efficiency is 40%�?0%, the high-pressure steam turbine is about 20%�?0%, and combustion gas turbine is about 20%�?0%. So fuel consumption is rather low about 178g/kWh. The power station form applied with heat and power cogeneration, has the higher whole energy conversion efficiency, and the thermal power gets more fully used.

 (3) The rapid starting and can quickly reach full power

The heavy fuel oil generating sets may use heavy fuel oil and light fuel, which could reach full

loaded operation in 3 min of emergent condition (light fuel oil used on emergency ), and in 10 min of normal operation condition (starting uses light fuel oil, and heat engine uses heavy fuel oil ),while the thermal & electricity steam power equipment generally needs 3�?h from starting to full load. What’s more, the shutdown process of diesel is rather short, started and shutdown frequently.

 (4) Simple maintenance, small conventional maintenance work, little operation staff, overhaul period of 36000h (related to the fuel oil quality), and low operation expense.

 (5) Convenient unit combination, capacity easy to extended

Each capacity of heavy fuel oil power station generating sets, ranging from 3000kw to 21000kw, which has the advantage of fitting for more power supply load with more selected capacity. When adopting heavy fuel oil power station generating sets as power, the installed capacity may dispose neatly according to actual need, which can increase power set capacity in the after enlargement & production. The expansion of access is simple and smart, so the expense of primary construction investment is much lower.

7.      Scope of supply

No.	Designation	Contents	Unit	Qty.	Installed location of machines	Remarks
1	7H32/40 generating sets	Engine, Auxiliary module ,shaft coupling, generator, public chassis, control panel	set	4	Power plant
2	Lube separating module	Including lube delivery pump, lube preheating device, lubricant separator, sump pump, sump tank, control switch cabinet, etc.	set	4
3	Fuel supply module	Conversion valve of heavy fuel oil and light oil, fuelmeter, viscosity control, fuel mixed tank, fuel pressure pump, HFO end heater, fuel cooler, fuel double filter, control switch cabinet	set	4
4	Leakage oil & decontamination module	Sludge pump discharge, fuel leaked oil tank, lube sludge tank	set	1
5	Engine preheating module	Preheating high temperature water, lubricating oil	set	2
6	Inlet filtration muffler module	Shutter, inlet filter, inlet muffler	set	4
7	Water maintenance module	Radiator, centrifugal water pump	set	1
8	Heavy oil separation module	HFO delivery pump, HFO preheating device, Separator, sump pump	set	2	Pump plant
9	Air container	Starting air container, working air container, pressure reducing valve	set	2
10	Air compressor	H.P. air compressor	set	2
11	Radiator	High /low temperature water heat dissipation	set	4
12	Exhaust Muffler	Exhaust Muffler	set	4
13	Exhaust boiler	Boiler body, air manifold, water pump, control switch cabinet	set	4
14	Switch cabinet	Switch cabinet of parallel generating sets	set	4
15	Feeder cabinet	Switch cabinet of total outgoing line	set	1
16	Neutral point resistance cabinet	Neutral point grounding of generator	set	4
17	PT cabinet	PT buscouple	set	1
18	DC panel		set	1
19	Power distribution cabinet	Power consumers and distributors of each module system	set	1

8.      Configure of power station system

8.1 Diesel generating sets

The generating sets mainly include diesel, duplex bearing generator, high elasticity shaft coupling and public housing. Diesel and duplex bearing generator are connected by high elasticity shaft coupling, which are also supported and fixed by public housing.

Function of diesel generating sets:

Rated power·········································3209kW   According to ISO3046

Site(Most Continuous Power)\speed···································· 3000kW

Rated speed··································· 750rpm   

Rated voltage··································· 11kV   

Rated frequency····························50Hz 

PF(Power factor)······································· 0.8     

Dry weight··············································· 77.1t    

The generating sets as the mai, n electrical power, no limitations for operation time; it can operate and supply electricity continuously except the normal maintenance.

8.1.1 Test and inspection

1) Shop test

Diesel engine shall be tested at the shop in accordance with ISO 3046 and manufacturer’s standard.

Load test

Diesel engine will be coupled with a generator and tested using marine diesel oil under the following loads and duration of test program.

   Load     Duration

50 %                0.5 hours

75 %                0.5 hours

100 %                1 hour

Other test shall be performed additionally as follows :

  -  Over speed trip test

-  Engine safety device test (as per HHI standard)

After the shop test, the engine is to be overhauled and inspected in the presence of the representative of the client for the chosen one (1) cylinder for the followings ;

-  Piston & connecting rod

-  Cylinder liner

-  Main bearing shell

-  Intake and exhaust valve

2) Site test (option)

Client shall perform commissioning and start-up with Contractor’s technical assistance.

 Followings shall be checked before or during commissioning;

-  Installation check

-  Engine & generator coupling and alignment check       

-  Test to prove correct operation of interlocks, alarm and tripping circuits       

-  Safety device simulation check

Site performance test

After successful start-up, performance test shall be done by client under the technical assistance and guidance of contractor’s supervisor(s) as follows as far as site conditions allow;

Load               Duration

50% load          1 hour

75% load          1 hour

100% load          1 hour

The performance test procedure will be submitted to the client.

8.1.2 Diesel

Brand and model of diesel······························ ZGPT- HYUNDAI 7H32/40 

Pattern································· L, four stroke, direct injection, turbocharger, air cooled, compressed air starting

Cylinder bore······························ 320mm 

Stroke································· 400mm  

Compressed ratio····························15:1  

MCR (Most Continuous Power)\speed·············· 3325kW/750 r/min   According to ISO3046

Site(Most Continuous Power)\speed················ 3108kW/750 r/min

Direction of rotation·························· Crankshaft clock-wise rotation (as viewed from output end)

Lowest steady speed··························· 250r/min 

Fuel consumption rate (When MCR happens) ·············· 181g/kW.h,tolerance+5% 

                                         (Lower calorific value of fuel 42700KJ/kg;

Without engine driven pumps; Tolerance+5%; At 100& load)

MEP (Mean effective pressure)   24.9Mpa

Pistons mean speed································· 10 m/s 

Air intake flow····································· 23700kg/ h 

Exhaust gas flow··································24400kg/ h

Exhaust gas temperature after supercharger················· 354^oC (300~400^oC)

Supercharger air pressure································ 2.5-3.5bar

Supercharger air temperature before cylinder·················· 45^oC (35~50^oC)

Exhaust main pipe temperature before supercharger···························450~570^oC

Most combustion pressure·································· 190bar

Diesel inlet lube pressure·································· 0.4~0.5MPa  

Diesel inlet lube temperature··································· 65^oC 

H.T. water into-machine pressure···································· 0.3~0.4MPa

H.T. water out-machine pressure······························ 90^oC  

Injector coolant water into-machine pressure···························0.4~0.9 MPa  

Injector coolant water into-machine temperature ···························60^oC   

Fuel into-machine pressure·····························0.4~0.8MPa  

8.1.3 Generator

Brand of generator·································· Leroy Somer/ ABB/ AVK /HYUNDAI

Generator output power\speed························· 4011.25kVA / 3209 kW

Direction of rotation··································· Counter clock-wise (as viewed from input end)

PF············································ 0.8 

Voltage, frequency·······································11kV 50Hz 

Efficiency·········································96.5% 

Grade of Protection············································ IP23 

Winding temperature sensory··························· 2×6Pt100 (sensory) (1 set standby)

Anti-freezing heater········································· AC230V 

Coolant method·············································· Self-fan coolant

AVR (Automatic Voltage Regulator)·················· Installed on generator

8.1.4 High elasticity shaft coupling

Connect the diesel and generator elastically in order to make sure the output power from diesel deliver to generator.       

8.1.5 Common base and elastically supported

Fix and support diesel and generator, internally install lube working oil tank and contain lube for diesel engine.

The gensets are mounted with resilient vibration-free isolators onto the foundation. Diesel engine lube oil, cooling water interface connect the outside piping through a flexible connection

Common base equipped with electric drive turning gear, the pre-oil pump, lubricating oil centrifugal filter, fuel leak alarm and bolts, adjust seat pad and so on.

8.1.6 Genset control, safety and monitoring system

1) Genset control and monitoring system

-  Woodward electronic governor (EN80 actuator and 723+ controller)

-  Pressure & temperature sensor

-  Exhaust gas temperature sensor

-  Main bearing temperature sensor

-  Local engine control panel including monitoring system to be provided

2) Engine /generator control panel

Engine/ Generator control panel will be metal-enclosed, free-standing, IP41, indoor installation.

Monitoring

-  Engine RPM display

-  T/C RPM display

-  Engine pressure display

     Starting air pressure   

     FO engine inlet pressure

     LO engine inlet pressure

     Charge air engine inlet pressure

     LT & HT cooling water engine inlet pressure

   -  Engine temperature display

FO engine inlet temperature

     LO engine inlet temperature

     Charge air engine inlet temperature

     HT cooling water engine in/outlet temperature

     LT cooling water charge air cooler in/outlet temperature

     Main Bearing temperature

     Exh. Gas T/C inlet temperature

-  Generator

     Bearing temperature

     Stator winding temperature

Control

-  D/G set emergency stop

-  Engine start and stop

-  Engine speed control

-  Generator voltage control

-  Remote/Local control selection

Engine safety

-  Overspeed

-  LO engine inlet low pressure

-  HT cooling water high temperature

-  Tacho failure

-  Main bearing high temperature

Protection relay (multi or single protective type)

-  Under/ over voltage protection

-  Reverse power protection

-  Loss of excitation

-  Overcurrent protection

-  Overcurrent ground protection

-  Under and over frequency protection

-  Lock out relay (separate type)

3�?/B>COMMON SYNCHRONIZING PANEL