As per the requirement of the Buyer, the Seller will supply equipment for 2MW Power Plant to Buyer. The power plant consists of 2 sets of generators, with capacity of 1000KW per set, installing capacity of 2MW. The rated voltage is 240/440V, and the frequency is 60HZ.

The generator set are capable for operation with Diesel oil and Tyre oil (TO), whereby the TO must be pre-treated by special equipments before enter the engine.

 

This power plant is designed as a continuous power plant in India and use tyre oil. (Client has supplied a specification of the oil).

The power plant consists of 2 sets of diesel generator, with capacity of 1000KW per set; Install capacity of 2MW. The power plant output voltage use 440V.

 

The specification outlines the scope of supply for each DG set;

The DG set is driven by diesel engine model G6300 manufactured by NBZCE Machinery Group Co., Ltd., which is the largest medium speed engine manufacturer in China;

The engine with benefit of low speed, large cylinder bore, individual injection pump for every cylinder and have successfully experience to use tyre oil in Italy.

NBZCE product the engine with its self intellectual property right, and can do special technical modify to client in different application fields.

 

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.

 

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 equipments and materials according to the scope of delivery;

Installation guide and commissioning of the power plant;

Operation training

 

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

 

Adopt freshwater as raw water.  If there doesn't have piping tap water, the raw water can be river water or well water.

Water for engine HT circuit shall be treated according to the international standard and the Chinese standard (GB).

 

DO (Diesel Oil) / TO (Tyre Oil) is the main fuel. DO is used for power plant start or used at engine stop period to flush fuel system in engine. TO needs to be purified treatment before entering the engine. The standards for clean oil should be fit, water content less than 0.2 Vol %, solid particles content less than 50mg/kg and size should less than 10μm.

 

The viscosity SAE 40 CD class lubricating oil is fit to running the generator.

Every engine lube oil capacity is 1500L with a individual external tank . After bending and welding all pipe work must be cleaned internally using an approved acid cleaning process. And all pipe inner wall should be inspected and ensure that no weld spatter, slag, rust or oxide remains.

The viscosity ISO VG68 class lubricating oil is fit to running the turbocharger. Total bearing house oil capacity of the turbocharger is 1.4L. The change interval of the turbine oil about 1000 hours.

 

The engine is started by means of compressed air through a rotary valve on it. The compressed air is supplied by motor driven compressor, and the air is storage in high pressure 3.0MPa receiver.

 

Cooling water system for engine adopts close (two loops) cooling system. Engine jacket cooling water uses fresh soften treated water, circulates by one engine driven water pump. Low temperature cooling water system adopts fresh water directly by on engine driven pump. The heat exchanger for the low water cooling water adopts cooling tower in this project.

 

Each engine should have its own exhaust pipe into open air. A flexible bellow has to be mounted directly to transition piece at turbocharge outlet, to compensate for thermal expansion stress and prevent damage to the turbocharge due to vibration. The bend should be made with largest possible bending radius. Minimum radius used should be 1.5D.

For power plant the residual heat in the exhaust gas system can be recovered by gas boiler to produce steam for heating fuel and other application in industry factory.

 

Two 1MW/440V generators will supply electricity to one 440V busbar terminal by synchronous control system. And auxiliary equipments take power from a LV distribution panel. In this project the LV distribution panel is prepared by client at site.

 

The main plant will be arranged in 2 lines:

The first line (control room) is for the electrical control room and switchgear rooms. Its second floor is for silencer. The distance of the columniation is 6 m; the span is 6m, length is 18m and height is 4m;

The second line (generator hall) is for DG, air compressor, air receiver, lube oil tank, etc, the span is 15m, length is 18m; there is a traveling crane (5t) in the room.

 

The total area of control room is 108 square meters with length of 18m, width of 6m and height of 4 m. The roof of the control room is of reinforced concrete construction, and is flat roof that is convenient for installing equipments on it. One silencer and its bracket with weight of 0.8 ton is arranged for each generator, total are 2sets, and total weight for 2 silencers is 1.6 tons.

Inside the control room, there are LV control room and switchgear. All LV cables will be connected to switchgears from alternator terminal through cable channels in the control room.

Double deck sound insulation glazing with length of 1800 mm, width of 1500 mm, and thickness of 8 mm is installed on the control room wall facing to the alternator end of the generator. The bottom of glazing shall be 800 mm above the ground.

Ventilation for the control room adopts air conditioner.

 

The total area of steel construction main building is 270 square meters with length of 18 m, width of 15m. The distance of the columniation is 6 m.

Main equipments in generator hall:

a.     2 sets of 1MW generators

Model: 1000GF1-2B6 ; Rated power: 1000kW; Rated speed: 514r/min; Weight for each generator:  31.5 tons including diesel engine 17.5 tons, alternator 12 tons and engine frame base 2 tons.

 

One water tank for soften water is arranged in auxiliary building. The soften water used for engine HT cooling water supply, oil separator operation water.

Another water pond is arranged in front side of the main building for engine LT water cooling system. The water pond is of reinforced concrete construction with length of 10 m, width of 3.15 m, and height of 3 m. The wall thickness of the water pond is 0.35 m.

2 cooling towers are installed on the water pond.

Model: GBL-50 cooling tower is used for LT water cooling.

Water supply and drain are designed for the water ponds.

 

All oil storages are not included in the scope of delivery.

Fireproofing wall with height of 1.6 m is arranged around the oil storage, earthing for avoiding thunder-strike shall be considered for the oil storage. 20m fire guard distance for tank yard and main building is considered.

The oil storage tank can be considered by client together with tyre oil production processing.

The oil tank should configure with raw oil storage tanks, purified oil tanks. The purified oil should be treated by oil centrifugal separator before enter engine. The clean oil can pump to daily tank of the power plant.

 

Diesel generating set:

According to the power capacity 2MW, the project plan configures 2 units of diesel generators.

Rating of the D.G. set 

Under above mentioned site conditions

-----------------------------------------------------------------------------------------------

       Rating at       Alternator       Rating at

       engine         efficiency       alternator

       crankshaft                     terminal(MCR)

       KWm             ( % )        KWe         KVA(0.8 pf)

-----------------------------------------------------------------------------------------------

Nominal        1103             94           1000       1250

Running   

-----------------------------------------------------------------------------------------------

Note : COP rating will be 90 % of MCR

Gen-set model                       1000GF1-2B6

Manufacturer                         NBZCE Machinery Group CO., LTD.

Rated voltage                        440V

Rated power factor                    0.8 Lag

Phase                               3p4L neutral grounding via reactor

Frequency                           60Hz

Rated speed                         514rpm

Stable frequency (rev.) regulating rate     �?.5%

Frequency (rev.)  fluctuation rate         ±0.5%

Transient voltage regulating rate         +20�?15%

Stabilizing time                         5S

Stable voltage regulating rate            ±2.5%

Voltage fluctuation rate                  ±1%

Range of voltage setting                95%~105% Un

Voltage regulation method              Brushless AVR

Gen-set rated power (PRP)             1000kW

1h power every 12h (LTP)              1100kW

Continuous power (COP)               900kW

Rated power output fuel consumption  210+3% g/kWh

Lubrication oil consumption           1.2+0.2g/kWh

Start time                            <5S

Installation method                   Common frame rigid installation

Overall dimensions:                   7500x2350x3060mm

Weight                              31.5T

 

G6300 TO engine is based on NBZCE Tyre oil know-how and with continuous running in Italy with tyre oil;

Large bore and long stroke with lower speed: 300mmx380mm, @ 514rpm;

Four valves with exhaust valve cooling design and valve turning machine;

Low NOx Emission;

Technical particulars for the diesel engine are as follows:

Number of cylinders               6

Arrangement of cylinders           In Line

Bore (mm) X Stroke (mm)          300 X 380

Type                                            4-stroke, direct injection, turbocharger after cooler

Rotational speed                    514 RPM

Mean effective pressure            16.5 Bar

at rated power & speed

Mean piston speed                 6.33 m/sec.

Rotation as seen from flywheel     Clockwise.

Swept volume per cylinder         26.875 litres

Combustion chamber volume         2.067 litres

Compression ratio                    13:1

Max. combustion pressure          125 bar

(at rated power/speed)

Power rating

Rated power under ISO Conditions

Maximum continuous rating (MCR)    1500 HP

at engine crankshaft

Corresponding rotational speed        514  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)     1500 HP

at engine crankshaft

The engine should be capable of accepting a sudden load as per the guidelines in ISO-8528-5-2007. As per this standard, the maximum sudden load increase stages are

 

         Baseload %     Sudden load   increase to %

--------------------------------------------------------------------------------

1st Stage          0%          50                50%

2nd Stage             50%         30                  80%

3rd Stage      80%          10                  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. 

 

Alternator is self-excited, brush less type in two bearing construction with single shaft extension and IP 23 enclosure. Alternator is fitted with bearing temperature detectors.

- Rated KVA                                               1250 KVA

- Power factor                                             0.8 lag

- Max. Alternator output at site                   1000 KW

- Duty                                                         Continuous

- Rated speed                                               514 RPM

- Output voltage                                         440V

- Efficiency at 100% load and 0.8 PF             95 %

- Direction of rotation                                 clockwise

- Number of poles                                             14

- Rated frequency                                             60 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

- Excitation and AVR type                           Brush-less, AVR

- Connection                                              3P

 

There are one 100m³TO storage tank, one 100m³DO storage tank,one 5m³sludge oil tank, one horizontal 5m³DO daily tank, and one 5m³TO daily tank is configured for the power plant. The daily horizontal tank should place about 3m above engine hall's floor.

The tyre oil product line makes the tyre oil from waste rubber. Tyre oil is supplied to the storage tank directly from the factory. 

The raw tyre oil in storage tank to settle down by physical gravity for pre-separation of sludge and ash. TO in storage tank will be pumped to the separator modules to clean the oil. The separating capacity for each separator unit is 1500 kilogram one hour. Two sets of TO separator configured as one works, one for standby. For whole power plant, the maximum TO consumption one hour is about 650 kilograms. The clean TO will be pumped to daily TO tank, and the sludge oil will be pumped to sludge oil tank through the sludge oil pump installed in separator module. Overflow pipe is provided between TO daily tank and storage tank.

TO in daily HFO tank and diesel oil in daily DO tank will be pumped to a mixture drum places before every generator in generator main building.

 

DO is used for gen-set starting and stop period. TO is used for continuous operation.

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:

Equipment delivered loose:

1)     Two TO separator set

TO supply pumps with suction filter.

Separator.

Heated sludge tank and sludge pump.

Water supply control valves and high placed water tank for operation.

Control and monitoring cubicle.

2)            Mixture drum with control valves

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 205 gms, when engine operates at Maximum Continuous Rating (MCR).

FUEL CONSUMPTION (with 5 driven pumps)

====================================================

         G6300ZD8            Consumption at engine Cr.shaft  

                            (514 RPM)                gm/kWh                                                    

====================================================

                100% Load              205.00

SITE      -----------------------------------------------------------------------------

          75% Load                203.00

CONDITION-------------------------------------------------------------------------

             50% Load                210.00

====================================================

The values are subject to a 3% tolerance and apply when burning fuel with a net calorific value of 10,200 KCal/Kg minimum.

 

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.

The total oil capacity of this lube oil tank is 1500 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.

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

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

Equipment delivered loose for every engine:

-      One tank for lube oil (1500 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)

 

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:

-      Two air compressors

-      Three air receivers of 300 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.

 

The cooling system of generator adopts close loop type, use fresh water as coolant. It comprises a low temperature circuit, a high temperature circuit. Low temperature water is cooled by cooling tower.

The LT circuit includes charge air cooler, lube oil cooler and HT water cooler. The LT water drawn by the water pump from the reservoir, the cooling water flows to the air cooler, the lube oil cooler, and the HT water cooler, then return to water cooling tower to cooling down.

The HT water circuits by water pump to enters the engine block and cylinder head. The cooling water is discharged out through the outlet water main pipe, and cooled in HT water cooler. An expansion water tank is placed for compensation and venting air and gas in cooling water. The circuit temperature is controlled by thermostatic valve. The HT and LT cooling water pumps are both centrifugal type and driven by the crankshaft through gear transmission.

One cooling tower with cooling capacity to be 50m3/h is arranged for each generator, total two cooling towers for whole plant.

Equipment fitted on the Engine:

-          Two engine driven water pump

-          One water-cooled charge air cooler

 

Equipment delivered loose:

-          One HT water cooler

-          One lube oil cooler

-          One compensation water tank

-          High temperature thermostatic valve

-          Air discharge valve

-          Cooling tower

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

 

The air intake system is equipped with air filtration (ABB type installed on the engine) to clean air.

One axial-flow explosion-proof fan 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.

 

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 6): 12.5g/kWh

Engine’s actual Nox Emission Value: 9.34g/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.

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:

-          Two exhaust silencers

-          Insulation /lagging/cladding for exhaust ducting

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

 

One water soften equipments is arranged for the power plant, water treatment capacity is 1000kg one hour.

The water soften equipment adopts resin exchanger treatment system.

Equipments for water soften system:

-          1 water soften equipment

-          2 water feed pump

-          One water tank

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

 

Two 1MW/440V HFO generators will supply electricity to an 440V busbar, and synchronous parallel running with loadsharing.

Power required for the power plant protective, control and supervisory system will be provided by means of 24 V DC 100Ah power supply system.

Operating power for ACB is take from generator terminal 440V.

 

The generator switchgear is used to deliver electricity from alternator to busbar.

1)            3 pole electrically operated Air Circuit Breaker (ACB)

2)            Metering / Protection CT and PT

3)            Meters, indicators

4)            Ammeter for every phase

5)            Voltmeter with selector switch

6)            ACB ON

7)            ACB OFF

8)            ACB spring energized

9)            Manual ACB ON/OFF

DMR-301P digital common relay is adopted for gen-set protection, which is used for alternator protection, switch control, monitoring, measuring, display and electrical failure record.

The following functions and protection can be carried out on the relay:

-          Voltage locked over current

-          Reverse power

-          Over current

-          Over voltage

-          Low voltage

-          Low frequency

-          Over frequency

-          Over load

-          Accurate measuring of all operation parameters such as power, voltage, current, frequency, power factor and others

-          Display the conditions of all switches

-          Running record and failure storage

10)         Control and operation functions

The generator switchgear 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, speed, and engine thermal parameters can be displayed on it.

Main functions for control and operation:

-          Starting engine

-          Speed control

-          Voltage adjustment

-          Load sharing mode select

-          Voltage measuring changeover

-          Current measuring

-          Frequency indication

-          Power indication

-          Excitation current indication

-          Speed indication

-          Engine thermal dynamical parameters

Pressure, temperature indication, including lube oil pressure, cooling water pressure, cylinders cooling water temperature, cylinder cooling water outlet temperature, engine exhaust temperatures, lube oil engine inlet /outlet temperature, water engine inlet/outlet temperature.

-          Alarm

11) 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 240V

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

 

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 2 cooling tower fans (3KWx3), 2 air compressor motors (5.5kWx2) and one DC power source panel (4kW), control and switchgear room ventilation air conditioner (3kWx2).

The lighting and air conditioner system is about 10kW, all lighting equipments are considered during civil work.

The fire fighting system includes 2 fire-fighting pumps (11kWx2) 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 20kW).

 

24VDC device

The DC system is supplied by a 24V, 100Ah DC power supply batteries. The batteries are charged by a AC240/DC24V 20A charger, with battery and charger state monitoring system.

 

Local Control Desk is provided for monitoring pressure and thermal parameters of the running engine. Also starting, stopping and speed control of engine is possible in local control operation mode. It is located near the engine.

Major Components in Local Control Desk

1)    Pressure gauges, switches

Lube oil filter inlet pressure

Lube oil filter outlet pressure

Lube oil in cylinder head inlet pressure

Cooling water pressure

2)    Temperature indication

Cylinders cooling water temperature scanner

   Cylinder cooling water outlet temperature measurement system with Cu50 thermo resistor for each cylinder and scanned by a multi-channel meter.

Engine exhaust temperatures scanner

   Pyrometric exhaust gas system with thermocouple for each cylinder and turbocharger, and scanned by a multi- channel meter.

Lube oil engine inlet /outlet temperature

Water engine inlet/outlet temperature

3)    Engine RPM indicator with cranking and over speed protection.

4)    Push buttons, indicating lamps, selector switches

- Common engine alarm

- Engine start permission

- Local / remote mode select

- Engine start / stop

- Flasher off

- Engine speed raise / low

- Emergency stop

 

The diesel engine will stop automatically in case of the following failures:

-          Very low lube oil pressure

-          Very high water engine outlet temperature

-          Engine over speed

The diesel engine will alarm automatically in case of the following failures:

-          Low lube oil pressure

-          Low water pressure

-          High lube oil temperature

-          High water temperature engine inlet

-          Alternator bearing temperature high

 

The generator adopts digital integrated relay protection system for monitoring and protection.

An ICBU-360 digital integrated relay is installed on generator switchgear, which is used for alternator protection, switch control, monitoring, measuring, display and SOE record.

The following functions are configured on the relay:

-          Differential current

-          Reverse power

-          Instant trip current

-          Voltage locked over current:

-          Over current

-          Over load

-          Earth failure

-          Over voltage

-          Under voltage

-          Low frequency

-          Over frequency

, <, TD vAlign=top width=259>

Model	G6300ZD8
Type	Inline, four-stroke, direct injection, turbocharged, and after cooled
Quantity	2 sets
Rated power	1103kw
514r/min
Bore/stroke	300/380mm
Starting method	Compressed air
Cooling system	Radiator close system
Dimension	4740×1580×2800mm
Weight	17500kg
Manufacturer	NBZCE Machinery Group Co., Ltd

Model	TF-1000
Type	Brush-less synchronous alternator
Quantity	2 sets
Rated power	1250KVA
Rated speed	514r/min
Rated voltage	440V
Frequency	60HZ
Power factor	0.8 lagging
Insulation class	F/F
Excitation	AVR
Weight	12000kg
Manufacturer	NBZCE Machinery Group Co., Ltd

Model	CZ-20/30F
Type	Single row vertical, differential piston two-stage compression, air cooled
Exhaust capacity	Min. 20m3/h
Quantity	2 sets
Rating pressure	3MPa
Cylinder bore	1st stage: 102mm, 2nd stage: 90mm
Piston stroke	65mm
Exhaust temperature	Max. 85°C
Rotary speed	1000r/min
Shaft power	<5kW
Motor	Y132S-6/5.5kW
Overall dimensions	970x440x700mm
Weight	155kg
Manufacturer	NBZCE Machinery Group Co., Ltd

Model	B500/3.24
Quantity	3 sets
Air inlet & outlet	�?33
Design pressure	3.24MPa
Working pressure	2.94Mpa
Max working temperature	�?80°C
Volume	500L
Manufacturer	NBZCE Machinery Group Co., Ltd

Model	GBL-50
Quantity	2 sets
Cooling capacity	50M3/H
Inlet water pressure	34 kpa
Temperature reduce	5-10°C
Fan power	3Kw
Net weight	930kg
Manufacturer	NBZCE Machinery Group Co., Ltd