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1MW HFO power plant Project Design Specifications
Drawings
Click here to view the Layout For 1MW HFO power plant 4/6 2013
Click here to view the Drawing of Steam System For 1MW HFO Power Plant 4/6 2013
Click here to view the Fuel System For 1x1MW Power Plant 4/6 2013
Click here to view the Lube Oil System For 1MW Power Plant 4/6 2013
Click here to view the Cooling Water System For 1MW Power Plant 4/6 2013
Click here to view the Exhaust gas and boiler system for 1MW power plant 4/6 2013
1. General
1.1 Design input
1.2 Project brief
As the requirement of the Buyer, the Seller will build a 1MW HFO Power Plant for the Buyer in Macedonia operating with heavy fuel oil. The power plant consists of one set of diesel generator, with capacity of 1000KW.
1.3 DG set configuration
The specification outlines the scope of supply for each DG set;
The DG set is driven by diesel engine model G6300ZD6 manufactured by NBZC, which is the largest middle speed engine manufacturer in China.
1.4 Standard & code
The design is according to the Chinese standard & code, in line with ISO/IEC standard. The project 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.
2. Design Fundamentals
2.1 Civil work:
The main building adopts steel structure. The under ground portion are reinforced concrete structure. According to the geological report supplied by the buyer, Seller will decide on the foundation design. The buyer must build according to the design drawing.
2.2 Fuel:
Heavy fuel oil is the main fuel.
2.3 Cooling water:
Adopt cooling tower open cooling system.
3. System specifications:
3.1 DG system:
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
3.1.1 1MW diesel engine:
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 500 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 500 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-8528-5-1993(e). As per this standard, the maximum sudden load increase stages are
Baseload % Sudden load increase to %
--------------------------------------------------------------------------------
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.
3.1.2 Alternator
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.
Technical data of Alternator
- Rated KVA 1250 KVA
- Power factor 0.8 lag
- Max. Alternator output at site 1000 KW
- Duty Continuous
- Rated speed 500 RPM
- Output voltage 400 V
- Efficiency at 100% load and 0.8 PF 94 %
- Direction of rotation clockwise
- Number of poles 12
- 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
- Excitation and AVR type Brush-less, AVR
- Connection 3P4W
3.2 Governor system for DG
Adopt hydraulic governor.
3.3 Daily oil tank
The Buyer shall supply the daily oil tank (about 5m3). Steam heater shall be installed in the tank, which is necessary for using heavy fuel oil.
3.4 Fuel Circuit system
Type of fuel:
The engines are suitable for operation on heavy fuel oil.
While starting or stopping the engine, diesel oil is used as fuel. When the water temperature at inlet to engine is more than 60 deg.C and heavy fuel oil is heated to the required temperature, the fuel can be changed from DO to heavy fuel oil through a 3-way fuel valve.
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) One heavy fuel oil separator set
2) One fuel viscosity control unit (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 rubber oil;
One flow meter for rubber oil;
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 Day Tank.
Fuel consumption:
The hourly rate of fuel consumption per Kilowatt Power delivered at the crankshaft flange at rated power & speed (after running in of the engine & for engine with driven water & lube oil pumps) is 200 gms, when engine operates at Maximum Continuous Rating (MCR).
FUEL CONSUMPTION
====================================================
G6300ZD6 Consumption at
(500 RPM) engine Cr.shaft
gm/kWh
====================================================
100% Load 200.00
SITE -----------------------------------------------------------------------------
75% Load 210.00
CONDITION-------------------------------------------------------------------------
50% Load 220.00
====================================================
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 30 %
Water temp. at charge air cooler inlet 25 deg. C
3.5 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 1000 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
Equipment delivered loose:
- One tank for lube oil (1000 ltrs capacity) with interconnections to the engine
- One electric motor driven lube oil-priming pump
- One manual lube oil-priming pump
- One lube oil cooler
- One centrifugal lube oil filter (FLL75 bypass type)
- One lube oil duplex type filter
3.6 Starting air circuit system
The DG is started by the compressed air.
One air compressor and one air receiver are arranged for the power plant, the capacity of air receiver is 500 liters, which is enough for starting one generator 7 times without intermediate refilling of the receiver.
High-pressure compressed air about 3 Mpa from the air receivers will be sent to the generator.
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:
- One air compressor
- One air receiver
3.7 Cooling water circuit system
Open cooling water circuit is adopted for the engine cooling.
Drawn by the water pump from the reservoir, the cooling 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 is cooled in a cooling tower.
One cooling tower with cooling capacity to be 50m3/h is arranged for the generator.
Equipment fitted on the engine:
- One engine driven water pump
- One lube oil cooler
- One water-cooled charge air cooler
Equipment delivered loose:
- One cooling tower (civil construction provided by the buyer)
3.8 Intake air and ventilation system
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 the generator shall be arranged for the main building on the engine side.
The axial-flow fan is used for supplying air for the generators and reducing temperature in the engine room through convection. The air will be discharged through natural ventilation on the upper side of the main building.
The Buyer shall consider the axial-flow fan during civil work.
3.9 Exhaust gas and environmental impact mitigatory system
Air pollution prevent
The diesel engine for the power plant is acquired international air pollution prevent certificate according to the provisions of Annex �?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 �?: 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 (DN300), 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.
One steam exhaust gas boiler is arranged for the power plant. One exhaust silencer (Residential type) is fitted to the 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:
- One exhaust silencer
- One exhaust gas boiler
- Insulation /lagging/cladding for exhaust ducting
- Complete interconnecting piping with flanges, fasteners, t-joints, butterfly valves, bosses, supports, etc as necessary.
3.10 Steam system
One exhaust gas boiler is arranged on the roof of control room. Heat exchange area for the boiler is 36m2, steam capacity for the boiler is 300kg one hour at 170 degree centigrade and 0.7 Mpa. Steam from boilers will flow to steam main pipe and divide to separator, oil storage and main building through main steam distributor and steam distributors. The main steam distributor is located on the roof of HFO equipment 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:
- One exhaust gas boiler
- Two water feed pumps
- Two Steam distributors
- Insulation /lagging/cladding for steam pipes
Complete interconnecting piping with flanges, fasteners, t-joints, valves, bosses, supports, etc as necessary.
3.11 Water soften system for exhaust gas boiler
One water soften equipment 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 (provided by customer)
Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.
3.12 Electrical system
3.12.1 Generator switchgear
The generator switchgear is used to deliver the generated output power to the consumer.
Major Components
1) 3 pole electrically operated Air Circuit Breaker (ACB)
2) Metering / Protection CT and PT
3) Kw / Kwh meter
4) Meters, indicators
5) Common protection relay
Metering devices
6) Ammeter for every phase
7) Voltmeter with selector switch
8) kWh account device
Indications
9) ACB ON
10) ACB OFF
11) ACB spring energized
Controls Possible
12) Manual ACB ON/OFF
Current Transformers
13) Metering / Protection CT
14) Excitation adjust wattless compensation CT
Potential Transformers
15) Potential transformer for Metering/Protection
Digital common protection relay
DMR-261 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
3.12.2 Control and operation panel
For the generator, one control and operation panel is supplied.
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, speed, and engine thermal parameters can be displayed on it.
Major Component in console
1) Control PLC
2) Automatic Voltage Regulator
3) Engine Frequency Monitoring Unit
4) 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
Engine cooling water temperature
Engine cooling water pressure
Engine lubricate oil temperature
Engine lubricate oil pressure
Engine exhausting gas temperature
6) Operation and indicators
Push buttons, change over switches
ACB engaged indication,
Engine start permission indication
Excitation control change over switch
DG ACB single or parallel operate select switch
DG ACB Trip and alarm indication
Gen-set running operate
Gen-set load sharing mode select
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 230V
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
Main functions on the control and operation panel:
- Starting engine
- Speed control
- Generator switch ON/OFF
- Voltage adjustment
- Load sharing mode select
- Synchronization
- 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
Main protection functions on the control and operation panel:
The Gen-set will stop automatically in case of the following failures occurred:
- Very low lube oil pressure
- Very high water engine outlet temperature
- Engine over speed
- Gen-set short circuit
The diesel engine will alarm automatically in case of the following failures occurred:
- Low lube oil pressure
- Low water pressure
- High lube oil temperature
- High water temperature engine inlet
- Alternator bearing temperature high
- Over load
- Voltage failure
- Over current
- Reverse power
3.12.3 LV auxiliary panel
A LV auxiliary panel is supplied for all auxiliary equipments including air compressors, cooling tower, HFO treatment equipment and others.
The auxiliary equipments for generator include 1 cooling tower motor (3KW), 2 air compressor motors (5.5kWx2), 1 booster motor (7.5kW), 1 HFO separator module (7.5kW), 2 boiler water feed pump motors (2.2kWx2) and one soft water pump motor (3kW).
4. Main equipments specifications
4.1 Diesel engine:
|
Model |
G6300ZD6 |
|
Type |
Inline, four-stroke, direct injection, turbocharged, and after cooled |
|
Quantity |
1 set |
|
Rated power |
1103kw |
|
Rated speed |
500r/min |
|
Bore/stroke |
300/380mm |
|
Starting method |
Compressed air |
|
Cooling system |
Open water cooling |
|
Dimension |
4740×1580×2800mm |
|
Weight |
17500kg |
|
Manufacturer |
|
Main parts of G6300ZD6 Diesel Engine
a. ABB turbocharger
b. GEA after cooler and lube oil cooler
c. Flexible coupling
4.2 Alternator
|
Model |
TFW-500 |
|
Type |
Brush-less synchronous alternator |
|
Quantity |
1 set |
|
Rated power |
1250KVA |
|
Rated speed |
500r/min |
|
Rated voltage |
400V |
|
Frequency |
50HZ |
|
Power factor |
0.8 lagging |
|
Insulation class |
F/F |
|
Excitation |
AVR |
|
Weight |
10200kg |
|
Manufacturer |
NBZC |
4.3 Air compressor
|
Model |
CZ-20/30F |
|
Type |
Single row vertical, differential piston two-stage compression, air cooled |
|
Exhaust capacity |
Min. 20m3/h |
|
Quantity |
1 set |
|
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 |
NBZC |
4.4 Air Receiver
|
Model |
B500 |
|
Quantity |
1 set |
|
Air inlet & outlet |
�?3 |
|
Working pressure |
2.94Mpa |
|
Volume |
500L |
|
Overall dimensions |
�?28x2305mm |
|
Weight |
468kg |
|
Manufacturer |
NBZC |
4.5 Cooling tower
|
Type |
GBL-50 |
|
Quantity |
1 set |
|
Cooling capacity |
50M3/H |
|
Inlet water pressure |
34 kpa |
|
Temperature reduce |
5�?0°C |
|
Fan power |
3Kw |
|
Net weight |
930kg |
|
Manufacturer |
Zhej Lianfeng |
4.6 Heavy fuel oil separator module
|
Model |
KYDH204CD-23 module |
|
Quantity |
1 set |
|
Rating treatment L/h | ,,
1000 |
|
Centrifuge Temperature |
90-98°C |
|
Light phase output pressure: MPa |
0.2MPa |
|
Separator motor |
7.5kW |
|
Sludge pump |
1.5kW |
|
Power source |
3P/400V/50Hz |
|
Material medium |
HFO |
|
Manufacturer |
NBZC |
4.7 Common Circulating & Booster module
|
Model |
CRGD-1.0 |
|
Fuel feed capacity |
1 m3/h |
|
Fuel circulating capacity |
1.6m3/h |
| Fuel supply pressure
|
0.2Mpa |
|
Fuel feed pressure |
0.4Mpa |
|
Max. fuel temperature |
135°C |
|
Rated fuel temper, ature rise |
4-5°C/min |
|
Viscosity before engine inlet |
9-13 cSt |
|
Viscosity deviation |
±1.5cSt |
|
Viscosity steady time | ,
Max. 3.5 mins |
|
Viscosity control accuracy |
Max. 3%
|
|
Primary filter |
80 mesh/inch2 |
|
Fine filter |
Max. 10-30µ |
|
Power source |
3P 400V 50HZ |
|
Power |
7.5kW |
|
Load |
5kW |
|
Manufacturer |
NBZC |
4.8 Exhaust Gas Boiler
|
Model |
LFL36-0.7 |
|
Rate steam capacity: |
300kg/hr |
|
Quantity |
1 set |
|
Steam pressure: |
7Bar |
|
Steam temperature |
170°C |
|
Safe pressure |
0.75Mpa |
|
Heating area |
36m2 |
|
Boiler back pressure |
Max. 220pa |
|
Waste gas inlet temperature |
350°C |
|
Waste gas outlet temperature |
200°C |
|
Overall dimensions LxWxH |
Ø1316x3430mm |
|
Weight |
3000kg |
|
Manufacturer |
NBZC |
| Offer for 1MW HFO generator |
|
|
|
|
|
|
|
| No. |
Item |
Qty |
Price(USD) |
Total(USD) |
|
| 1 |
Standard 1MW/0.4kV/50HZ generating set |
1 |
220000 |
220,000 |
|
| 2 |
generator auxilairy device, including |
1 |
14500 |
14,500 |
|
|
Lubricant tank |
1 |
|
|
|
|
Silencer |
1 |
|
|
|
|
Exhaust pipe |
1 |
|
|
|
|
Exhaust expansion joint |
1 |
|
|
|
|
Cooling tower |
1 |
|
|
|
| 3 |
Electrical device |
　/TD>
| |
|
|
|
LV auxiliary panel |
1 |
7800 |
7,800 |
|
| 4 |
HFO euipments |
|
|
|
|
|
HFO separator module |
1 |
30000 |
30,000 |
|
|
Common Circulating & Booster module |
1 |
35000 |
35,000 |
|
|
Exhaust gas boiler and soft water treatment device |
1 |
22500 |
22,500 |
|
| 5 |
Fuel storage |
|
|
|
All fuel tanks shall be provided by customer himself |
| 6 |
Installing materials |
　/TD>
| 　/TD>
| 　/TD>
| |
|
Mechanical installing materials for connecting equipment provided by supplier only |
1 set |
14000 |
14,000 |
We can provide material list, and purchased by customer himself. |
|
Electrical installing materials for connecting equipment provided by supplier only |
1 set |
21500 |
21,500 |
| 7 |
Spare parts and special tools |
1 |
|
|
|
| 8 |
Documents |
1 |
|
|
|
|
Total |
|
|
365,300 |
|
|
|
|
|
|
|
| Notes: |
|
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|
|
|
1. All prices base on FOB Ningbo. |
|
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|
|
2.Quality guaranty: Provide full warranty within one year from the date of delivery or 2000 operating hours, whichever comes first. |
|
|
3.Date of delivery: 3 months after date of contract. |
|
|
4. Payment: 30 percent advance payment by T/T, 70 percent by confirmed L/C. |
|
|
5. Valid date for the offer: before Aug. 31, 2013 |
|
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6. Installation guide and test: |
|
|
|
|
|
a.USD 1500 salary per month for one engineer (total 1-2 persons) during installation supervision and test (about 2 months). |
|
|
b.USD 1500 salary per month for one engineer (total 1-2 persons) during training and running (about 1 month). |
|
|
c.The costs for traveling between China and customer, lodging and food shall be borne by customer. |
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