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5x2MW HFO power plant project design specifications part 1
1.1 Project brief
This power plant is designed as main source in Sudan.
The power plant consists of 5 sets of diesel generators, with capacity of 2000KW per set; Install capacity of 10MW.
1.2 DG set configuration
The specification outlines the scope of supply for each DG set;
The DG set is driven by diesel engine model GN8320ZD manufactured by NB ZhongceDongl1 Co., Ltd Group Co., Ltd., which is the largest middle speed engine manufacturer in China;
The engine will use diesel and marine diesel oil as fuel.
1.3 Standard & code
The design is according to the Chinese standard & code, in line with ISO/IEC standard. The project is designed under the merit of “advanced technology, highly efficiency, safety, economy and practicality�?
The installation and the commissioning should be in line with the above standard & code.
1.4 Project scope
The scope of the Seller:
Engineering design of the power plant, including power system, fuel system, lubricating oil system, starting air system, cooling water system, air intake & exhaust, compressed air system, control & measuring system, electrical system, etc;
Supplying complete equipments and materials for building the power plant according to the scope of delivery;
2. Design Fundamentals
2.1 Civil work:
The civil works of the power station and fuel storage are NOT in Supply Scope. The Seller will provide the following drawings and technical information, which will assist civil consultant in designing the foundation and powerhouse.
- General assembly drawing
- Powerhouse layout
- Foundation plan.
- Schematic piping diagram.
The Buyer shall provide the following data for information and use:
. Soil bearing capacity
. Dynamic characteristics of soil
2.2 Soft water:
Water for DG will use soft water.
2.3 Fuel:
Use diesel and marine diesel oil.
2.4 Cooling water:
Adopt radiator cooling system.
2.5 Electricity:
3. General arrangement:
3.1 The main plant
The main plant will be arranged in 2 lines:
The first line is for the electrical control room and switchgear rooms. The second floor is for exhaust gas pipe and silencer. The distance of the columniation is 6 m; the span is 6 m, length is 42M;
The second line is for DG, air compressor, air receiver, lube oil tank, etc, the span is 18m, length is 42m; there is a traveling crane (10t) in the room.
3.2 Equipments arrangement:
Fuel storages and pump station are arranged near the main building, the fireproof wall must be built around the fuel storages;
The aeration and dust removal adopt natural recycling type;
The power transmission lines in the power plant are arranged in the cable channel under the ground or use the cable tray.
4. System specifications:
4.1. Diesel generating set:
Rating of the D.G. set
Under above mentioned site conditions
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Rating at Alternator Rating at
engine efficiency alternator
crankshaft terminal(MCR)
KWm ( % ) KWe KVA(0.8 pf)
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Nominal 2206 94 2000 2500
Running
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Note: COP rating will be 90 % of MCR
4.1.1 2MW diesel engine:
Technical particulars for the diesel engine are as follows:
Number of cylinders 8
Arrangement of cylinders In Line
Bore (mm) X Stroke (mm) 320 X 380
Type 4-stroke, direct injection, turbocharger, after cooler
Rotational speed 600 RPM
Mean effective pressure 18 Bar
at rated power & speed
Mean piston speed 7.6 m/sec
Rotation seen from flywheel Clockwise
Swept volume per cylinder 30.5 litres
Combustion chamber volume 2.35 litres
Compression ratio 13:1
Max. combustion pressure 130 bar (at rated power/speed)
Power rating
Rated power under ISO Conditions
Maximum continuous rating (MCR) 3000 HP
at engine crankshaft
Corresponding rotational speed 600 RPM
Under the following limiting ambient conditions:
Air temp. at turbocharger inlet 45 deg. C
Water temp. at charge air cooler inlet 32 deg. C
Deration to power applicable for engine 0 %(nil)
Beyond the abovementioned limiting conditions, deration to power as per ISO 3046 will be applicable.
Rated Power under site conditions mentioned above:Maximum continuous rating (MCR) 3600HP at engine crankshaft
The engine should be capable of accepting a sudden load as per the guidelines in ISO-8528-5-1993(e). As per this standard, the maximum sudden load increase stages are
Baseload % Sudden load increase to %
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1st Stage 0% 40 40%
2nd Stage 40% 30 70%
3rd Stage 70% 20 90%
4th Stage 90% 10 100%
During each of the above-mentioned stages of sudden loading, the transient speed drop will be restricted to a maximum value of 10% of the rated speed.
4.1.2 Alternator
Three phase brushless synchronous AC Alternator, which consists of main generator, AC exciter, and rotating silicon rectifiers. Six terminals for main generator have leaded out for HV. output, three for power supply, three for star connection and protect. LV auxiliary winding and harmonic winding in main generator feed supply for excitation circuit. Generator is fitted with bearing temperature detectors.
Technical data of alternator
- Rated output kVA 2500 KVA
- Power factor 0.8 lag
- Max. Alternator output at site 2000 KW
- Duty Continuous
- Rated speed 600 RPM
- Rated voltage 11000 V
- Rated Current 131.2A
- Efficiency at 100% load and 0.8 PF �?5%
- Direction of rotation clockwise
- Number of poles 10
- Rated frequency 50 Hz
- Over-speed 20% for 2 minutes
- Overload capacity and duration 10%, for max. 1 hr in every 12 hrs
- Insulation class F
- Enclosure IP 23
- Temp. rise class F (limits of Class B)
- Excitation and AVR type Brush-less, AVR
- Connection Star
NOTE
Alternator design considers harmonics in load.
4.2 Governor system for DG
Woodward 2301D digital control and UG actuator are adopted for load sharing and speed control of diesel generator. The performance characteristics of the generator set meets with ISO 8528 G2 Class. The parallel operation between each and/or all diesel gen-sets in island and grid mode is allowable. The synchronizing operation for the power plant can by manual and automatic.
The 2301D is a microprocessor-based digital control. The control is housed in a sheet-metal classis and consists of a single printed circuit board. The 2301D is configured using a computer with Woodward Watch Window software. The computer connects to the 2301D through a 9-pin connector (RS 232 port). The control operates from a 24Vdc supply. The actuator output, one analog input, and one analog output are configurable. The 2301D features dual dynamics and soft load transfer, to and from a bus. The 2301D includes one load sensor circuit, one actuator driver, one MPU speed sensor, one configurable analog output, one configurable analog input, eight discrete inputs and four discrete outputs. The 2301D operates within a range of �?0 to +70�?
The 2301D provides load sharing and speed control of diesel generator. The 2301D has four operating modes �?speed control, isochronous load sharing, droop base load, and isochronous base load.
Woodward UG-A is a hydraulic powered electric actuator. The UG-15 provides the muscle for 2301D. The UG-A takes a given electrical input signal and converts it to a proportional hydraulic output-shaft position to control engine flow.
4.3 Oil storage
All oil storages and fuel unloading pumps shall be provided by customer themselves.
4.4. Fuel Circuit system
4.4.1 Type of fuel:
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:
1) Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses, supports, etc as necessary up to Day Tank.
Fuel consumption:
The hourly rate of fuel consumption per kilowatt 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 198 gms, when engine operates at Maximum Continuous Rating (MCR).
FUEL CONSUMPTION (with 3 driven pumps)
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G8320ZD Consumption at
(600 RPM) engine Cr.shaft
gm/kWhr
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100% Load 198.00
SITE -----------------------------------------------------------------------------
75% Load 205.00
CONDITION-------------------------------------------------------------------------
50% Load 212.00
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The values are subject to a 3% tolerance and apply when burning fuel with a net calorific value of 10,200 KCal/Kg minimum.
4.5 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.
The total oil capacity of this lube oil tank is 2000 ltrs.
Lube oil consumption
The average lube oil consumption is 1.2 gm/kwh (+/- 0.2 gm/kwh) at MCR at crankshaft for a well-run engine.
Continuous centrifuging is essential for lube oil when operating on Furnace Oil.
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:
- One tank for lube oil (2000 ltrs capacity) with interconnections to the engine
- One electric motor driven lube oil-priming pump (option)
- One manual lube oil-priming pump
- One lube oil cooler
- One centrifugal lube oil filter (FLL75 bypass type)
4.6 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 receivers 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.
4.7 Cooling water circuit system
Radiator is arranged for each generator, and an electric water pump is arranged for the water circuit system.
Drawn by electric water pump from radiator, cooling water flows to air cooler, lube oil cooler, and then enters the inlet water main pipe and turbocharger. The cooling water is discharged out through the outlet water main pipe. Finally the water is cooled in the radiator.
Equipment fitted on the engine:
- One lube oil cooler
- One water-cooled charge air cooler
Equipment delivered loose:
- Five radiators (outdoor type)
- Five electric water pumps
- Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.
4.8 Intake air and ventilation system
The air intake system is equipped with air filtration (ABB type installed on the engine) to clean air.
Five axial-flow explosion-proof fans opposite to each generator are 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.
4.9 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. 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:
- Five exhaust silencers
- Insulation /lagging/cladding for exhaust ducting
- Complete interconnecting piping with flanges, fasteners, t-joints, butterfly valves, bosses, supports, etc as necessary.
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