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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.
�?/B>. General layoutThis 6 x 5.5 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 8 DG sets for15 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.
�?/B>. Diesel generating setCHF5000/11000 DG set consists of one set of MAN 12V32/40 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 CHF5500/11000
Rated power 5500 kW
Rated voltage 11kV
Rated current 328 A
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 101 ton
※External dimension(L×W×H) 11,045 x 3,365 x 4,850 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 TFW5100-8/2150
Rated power 5100kW
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 �?%
�?/B> 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 4 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 and contaminated 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 4 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/PlantLT 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
�?/B>. 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
Primary cablingThe primary cabling of the Plant is 11KV single bus. The output of 2 DG sets are all connected to 11KV bus. The final outgoing circuit and outgoing way shall be decided after confirmation with the customer. In this proposal the power output circuit is designed as two circuits output and the outgoing way as geosyncline cables.
In the 11kV bus of primary cabling diagram, the factory power supply is taken from the 11kV bus via 11kV/0.4kV factory transformer. The 11KV electrical cubicles for primary cabling are XN2 fixed switch cubicle. The main equipment includes generator output cubicles, PT cubicles, neutral earthing cubicles, CT cubicles, outgoing switch cubicle and factory power transformer switch cubicle.
1 . Generator output cubicles
Automatic and manual breaker close and trip switch
Differential protection current signal
Generator neutral earthing fault protection
Circuit-breaker and motor heater interlock with fan motor.
Stop the generator heater when close the generator outgoing circuit-breaker and start the generator ventilation motor simultaneously. Stop the motor when the circuit-breaker trip.
Enable the manual and electrical operation of close and trip.
2. Neutral earthing cubicles
Supply the differential protection circuit current signal
Supply voltage signal for exciting automatic regulator
Supply current signal for zero sequence protection circuit
3. PT cubicle
Supply voltage signal for active power, reactive power, three-phase current, power factor and frequency measure.
Supply generator protection voltage signal
4. CT cubicle
Supply current signal for excition regulation and active and reactive power meter
Supply generator protection voltage signal
5. Outgoing cubicle
Supply outgoing circuit for power users.
6. Factory transformer switch cubicle
Supply power to factory transformer
7. PT cubicle
Supply bus voltage
Equipped with bus PT
Secondary circuitThe secondary system of the Plant includes mainly he control, protection and monitoring system which uses normal magnetic relays. Generator protection and the protection of transformer and wirings are realized through integrated protection devices. The secondary protection devices are integrated into one control panel, which are installed in the control room.
DG sets and 11KV busbar use the manual synchronizer to realize the grid paralleling. The voltage and frequency regulation for grid paralleling is realized through central control table.
DG sets protection in secondary system contains the following :
- Differential protection
- Reverse power protection
- Overload protection
- Over voltage protection
- Combined under voltage and over current protection
- Neutral earthing protection
- Quick trip and over current protection for 11KV busbar outgoing switch
The electrical data of all DG sets are gathered at the central control table and displayed, recorded and printed by computer.
DC systemThe DC power system of the Plant has two types of load current i.e. DC24V 20AH and DC110V 80AH.
The diesel engine and related instruments use DC24V. DC110V is used for main control room and other Plant control systems, protection and communication, and emergency lighting system.
Performance data detectionThe performance data of all DG sets are communicated to the central control table and displayed, recorded and printed by computer.
- Air temp. at turbocharger inlet
- LT water temp. at air cooler inlet
- HT water temp. at engine outlet
- Lube oil temp. at engine inlet
- Lube oil pressure at engine inlet
- Pressure in LT water pipe
- HT water pressure at engine inlet
- Max explosion pressure
- Gas temp. at cylinder outlet
- Average exhaust gas temp., on one bank
- Exhaust gas temp. at turbine inlet
- Exhaust gas temp. at turbine outlet
- Vacuum at turbocharger inlet
- Exhaust backpressure at turbocharger outlet
- Turbocharger speed
Main alarms of DG setsTemperature
- HT water temp. at engine outlet
- Lube oil temp. at engine inlet
- Lube oil temp. at turbocharger outlet
- Exhaust gas temp. at cylinder outlet
- Average exhaust gas temp. on each bank
Pressure
- Lube oil pressure at engine inlet
- Lube oil pressure at turbo charger inlet
- Fuel oil pressure at engine inlet
- Pressure in overspeed protection air receiver
Safety stop
- Overspeed protection
- Low lube oil pressure at engine inlet
- High HT water temp. at engine outlet
Engine controlThere are two control mode for engine i.e. local control and central control, which can be selected by the local switch. The local control can facilitate maintenance and inspection works. Besides the instruments for easy monitoring, the local control panel also contains control elements for starting, stop, emergency stop and speed regulation, which enable the start, stop, overspeed protection, emergency stop and local/central switchover operations. Each DG set is equipped with one LCP. Part of performance data such as engine speed, start air pressure, engine lube oil pressure at engine inlet are monitored by the special instruments.
Auxiliaries controlControl of auxiliaries of engine includes:
Fuel oil pump
Lube oil pump
HT water pump
LT water circulating pump
Injector cooling water pump
Rockerarm lube oil pump
Turning gear motor
start air compressor
Generator ventilation motor (half pipe type )
Generator heater
The start and stop of most auxiliary pumps are controlled by the units in this system. Auxiliary unit shall have its own local control box. Some auxiliaries are controlled in distributing room.3 DG sets share one panel .
Factory power supplyThe factory power supply is taken from 11kV bus via the 1250kVA transformer to lower the voltage from 11kV down to 0.4KV and connected to switchgear which supplies power to auxiliaries control system and for workshop lighting, ventilation, security and common equipment. There is automatic power factor compensation device on the 0.4KVbusbar to guarantee the efficiency of DG sets and power supply quality.
�?/B>. Project and scope of supplyDesign and building of all the buildings and facilities within the Plant. Laying of cooling tower cooling pipes for the Plant.
BoundaryThe interface between the 11kV bus and the city grid is the outer side of the outgoing bus switch.
The water supply will come from the city water supply system. The interface is at 1 meter outside of the territory of the Plant.
The drain water of the Plant will go to the infiltration basin outside of the Plant.
The interface between the communication system and the city communication network is at 1 meter outside of the territory of the Plant
Scope of supply
SXD: To be supplied by SXD CT: To be supplied by Customer
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