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Diesel Generator Proposal

Power Plant Proposal

Home > Equipments > HFO Diesel generator & Marine HFO Engine - Technical Proposal and Offer of 4x2.5MW HFO Power Plant


 

Technical Proposal and Offer of 4x2.5MW HFO Power Plant

Drawings:

Click here to view the Layout drawing for 4x2.5MW HFO Power Plant 5/7 2013

Click here to view the boiler and silencer arrangement 5/7 2013

Click here to view the single line drawing for 4X2.5MW HFO Power Plant 5/7 2013

Click here to view the Compressed air system 5/7 2013

Click here to view the Engine cooling system 5/7 2013

Click here to view the Steam system 5/7 2013

1.    General
1.1   Design input
4x2.5MW 11kV power plant in Indonesia
1.2   Project brief
This power plant is designed as main source in Indonesia.
The power plant consists of 4 sets of diesel generators with capacity of 2500KW per set, install capacity of 10MW.
 
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 GN8320ZD12 manufactured by ND, which is the largest middle speed engine manufacturer in China;
The engine will use heavy fuel oil (380cSt/50°C)as fuel.
 
1.4    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.
 
1.5   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;
Supply equipments and materials according to scope of delivery list.
 
2.    Design Fundamentals
2.1 Civil work:
The civil works of the power station and fuel storage are NOT included 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 generator and exhaust boiler shall be softened according to the international standard and the Chinese standard (GB).
 
2.3 Fuel:
HFO (Heavy Fuel Oil) and diesel oil are the main fuel. The HFO need to be treated before entering the generator. The fuel treatment equipments for this power plant are designed according to heavy fuel oil.
 
2.4 Cooling water:
Adopt cooling tower for cooling, and use city pipe water for cooling water.
 
2.5 Electricity:
Four 2.5MW/11kV HFO generators will work in parallel, supply electricity to one 11KV bus-bar and feed out through one main outgoing panel. The LV electricity source for the power plant is supplied by a 500KVA transformer from the 11kV bus-bar.
 
3.    General arrangement:
3.1 Main building
The main building will be arranged in 2 lines:
The first line (Control room) is for the electrical control room, switchgear room, water soften treatment room and air compressor, air receiver. The second floor is for steam exhaust gas boilers and silencers, boiler is hypaethral layout. The distance of the columniation is 6 m; the span is 8 m, length is 42M and height is 4 m;
The second line (Generator hall) is for DG, lube oil tank, booster, etc, the span is 18m, length is 54m; there is a traveling double girder crane (10t) in the room.
a.     Control room
The total area of control room is 336 square meters with length of 42m, width of 8m 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 are arranged for each generator, total are 4 sets, and total weight for 4 silencers is 3.2tons. An exhaust gas boiler with weight of 5 tons is arranged for every two generators, total is 2 boilers, and total weight for 2 boilers is 10 tons. For each boiler, girder for bearing the weight shall be arranged.
Inside the control room, there are HV switchgear room, LV control room, water soften treatment room and air compressor room. All HV and LV cables will be connected to switchgears or control panels through cable trenches 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.
b.    Generator hall
The total area of steel construction main building is 756 square meters with length of 42 m, width of 18m. The distance of the columniation is 6 m. A 10 tons double girder bridge crane with span of 16.5 m is installed in the generator hall. The installing height of columniation for crane railway is 7 m, and its total height is 9.6m. The maximum height of the main building is 12.8 m.
 Main equipments in generator hall:
a.     4 sets of 2.5MW generators
Model: 2500GF1-3A; Rated power: 2500kW; Rated speed: 600r/min; Weight for each generator: 50 tons including diesel engine 28 tons, alternator 18 tons and engine frame base 2.8 tons.
b.    One set of fuel booster module for fuel viscosity control;
Weight for the fuel booster module: 2.3 tons.
c.     Two sets of HFO separator module for HFO purified;
Weight for the separator module: 1600kg.
d. Three model CZ-20/30F air compressors with four receivers for start air.
 
3.2 Water pond
One water pond is arranged besides the main building. The water pond is of reinforced concrete construction with length of 21.4 m, width of 4 m, and height of 3 m. The wall thickness of the water pond is 0.3 m.
Four cooling towers are installed on the water pond.
Cooling tower specifications:
Model: GBL-100; Fan diameter: 1800mm, Fan motor: 5kW, Dry weight: 1800kg, Wet weight: 2000kg.
Water supply and drain are designed for the water pond.
 
3.3 Oil storage
Total area for oil storage is 700 square meters with length of 50 m and width of 14 m. The following oil storages are arranged:
a.     Two heavy fuel oil storages with volume of 600 cubic meters, storage diameter of 9.55 m, height of 9 m, dry weight of about 60 tons and total weight of 660 tons for each oil storage. The intensity of foundation shall be fully considered.
b.    One diesel oil storage with volume of 250 cubic meters, storage diameter of 7m, height of 7 m and total weight of 280 tons. The intensity of foundation shall be fully considered.
c.     Two buffer heavy fuel oil tanks with volume of 50 cubic meters, storage diameter of 3.8 m, height of 4.5 m and total weight of 60 tons.
d.    One daily HFO tank, one daily DO tank and one residual oil tank with volume of 30 cubic meters, tank diameter of 2.8 m, length of 6 m and total weight of 35 tons for each oil tank.
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.
Notes: All fuel storages are not included in the offer.
4.System specifications:
4.1.  Diesel generating set:
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        2647             95          2500       3125
Running   
-----------------------------------------------------------------------------------------------
Note: COP rating will be 90 % of MCR
2.5MW 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            21.7 Bar
at rated power & speed
Mean piston speed                  7.6 m/sec.
Rotation seen from flywheel        Clockwise.
Swept volume per cylinder         30.578 litres
Combustion chamber volume         2.352 litres
Compression ratio                    13:1
Max. combustion pressure         140 bar
(at rated power/speed)
 
Power rating
Rated power under ISO Conditions
Maximum continuous rating (MCR)    3600 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)     3600 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.
 
Alternator
Alternator is self-excited, brush less type in two bearing construction with single shaft extension and IP 23 enclosure. Alternator is fitted with winding and bearing temperature detectors.

Technical data of Alternator

- Rated KVA                                           3125 KVA
- Power factor                                         0.8 lag
- Max. Alternator output at site               2500 KW
- Duty                                                     Continuous
- Rated speed                                           600 RPM
- Output voltage                                     11000 V
- Efficiency at 100% load and 0.8 PF         95%
- 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
- Excitation and AVR type                       Brush-less, AVR
- Connection                                          Star
 
4.2 Governor system for DG
Woodward 2301D digital control and UG15 actuator are adopted for load sharing and speed control of diesel generator.
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 -40 to +70°C.
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-15 is a hydraulic powered electric actuator. The UG-15 provides the muscle for 2301D. The UG-15 takes a given electrical input signal and converts it to a proportional hydraulic output-shaft position to control engine flow.
 
4.3 Fuel Circuit system
Type of fuel:
The engines are suitable for operation on DO (Diesel Oil) / HFO (Heavy Fuel Oil or Furnace Oil with maximum viscosity 380 cst at 50 deg. C.);
While starting or stopping the engine DO (Diesel Oil) is used as fuel. When the water temperature at inlet to engine is more than 60 degree centigrade and HFO (Heavy Fuel Oil) is heated to the required temperature, the fuel can be changed from DO to HFO through a change-over oil tank.
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)     Two HFO separator  module
2)            One fuel viscosity control module (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 HFO;
One flow meter for HFO;
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 Daily Tank.
 
FUEL CONSUMPTION (with 3 driven pumps)
====================================================
         GN8320ZD12           Consumption at  engine Cr.shaft
                                                      g/kWh
====================================================
                100% Load              198.00
SITE      -----------------------------------------------------------------------------
          75% Load                202.00
CONDITION-------------------------------------------------------------------------
             50% Load                211.00
====================================================
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                          60 %
Water temp. at charge air cooler inlet       25 deg. C
Site Conditions (Assumed)
Air temp. to turbocharger inlet              45 deg. C
Atmospheric pressure                     750 mm Hg
Relative humidity                          60 %
Water temp. at Radiator outlet             52 deg. C
The heavy fuel oil from daily HFO tank and diesel oil from daily DO tank will be pumped to the mixing vessel on the booster module through two fuel feed pumps. After heated by steam, the heavy fuel oil (or diesel oil) with constant viscosity about 10-14 cst will be pumped to fuel main pipe. The booster module is used for controlling viscosity and supplying fuel for generators. Fuel-supplying capacity for the booster module is 3000 kilograms one hour (Maximum feed capacity is 6000kg one hour, return oil is 3000kg one hour). Return oil from each generator will back to the mixing vessel through return main pipe.
Fuel change between HFO and DO can be achieved through the 3-way valve on booster module.
 
4.4  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 liters.      

Lube oil consumption

The average lube oil consumption is 1.2 g/kWh (+/- 0.2 g/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 (option)
-      Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses, supports, etc as necessary.
Equipment delivered loose:
-   4 tanks for lube oil (2000 ltrs capacity) with interconnections to the engine
-      4 electric motor-driven pre-lubrication pumps
-      4 manual lube pre-lubrication pumps
-      4 lube oil coolers
-          4 centrifugal lube oil filters (FLL75 bypass type)
-          4 lube oil duplex type filters
-          Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses,    supports, etc as necessary.
 
4.5 Starting air circuit system
The DG is started by the compressed air.
Equipment fitted on the engine:
Compressed air starting equipment including:
-      One compressed air filter
-      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 bottles 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.
 
4.6 Cooling water circuit system
The engine cooling is achieved by open cooling water circuit.
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 100m3/h is arranged for each generator, total four cooling towers for whole plant.
Equipment fitted on the engine:
-      One engine driven water pump 
-            One lube oil cooler
-            One injector cooler
-      One water-cooled charge air cooler
Equipment delivered loose:
-          Four cooling towers (civil construction provided by the buyer)
Complete interconnecting piping with flanges, fasteners, valves, bosses, supports, etc as necessary.
 
4.7 Intake air and ventilation system
The air intake system is equipped with air filtration (ABB type installed on the engine) to clean air.
For 4 diesel generators, air consumption is 62500m3/h. 4 axial-flow explosion-proof fans 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. The quantity of heat dissipated from the generators is about 2100 MJ/h. The air will be discharged through natural ventilation on the upper side of the main building.
 
4.8 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 VI 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 VI): 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 (DN400), 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.
Two steam exhaust gas boilers are arranged for the power plant. 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:
-          4 exhaust silencers
-          2 exhaust gas boilers
-          Insulation /lagging/cladding for exhaust ducting
-          Complete interconnecting piping with flanges, fasteners, t-joints, butterfly valves, bosses, supports, etc as necessary.
 
4.9 Steam system
Two exhaust gas boilers are arranged on the roof of control room. Heat exchange area for each boiler is 80 m2, steam capacity for each boiler is 700kg one hour at 170 degree centigrade and 0.7 Mpa. Steam from boilers will flow to steam main pipe and divide to separator and pump room, oil storage and main building through main steam distributor and steam distributors. The main steam distributor is located on the roof of control 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.
Equipments for steam system:
-          2 exhaust gas boilers
-          4 water feed pumps
-          3 Steam distributors
-          Insulation /lagging/cladding for steam pipes
Complete interconnecting piping with flanges, fasteners, t-joints, valves, bosses, supports, etc as necessary.
 
4.10 Water soften system for exhaust gas boiler
One water soften equipment (double module) is arranged for the power plant, water treatment capacity is 2000kg one hour.
The water soften equipment adopts resin exchanger treatment system.
Equipments for water soften system:
-          One water soften equipment (double module)
-          Two water feed pump
-          One water tank
-          Complete interconnecting piping with flanges, valves, bosses, supports, etc as necessary.
 
4.11 Electrical system
4.11.1 H.V. system
Four 2.5MW/11kV HFO generators will work in parallel, supply electricity to one 11KV bus-bar and feed out through one main outgoing panel.
11kV generator system
Four 2.5MW/11kV diesel generators are arranged for the power plant. For each one generator, the standard configure includes one switchgear for generator output and potential transformer, one control and operation panel (COP) and one local control desk (LCD).
The neutral of the generator is earthed through surge arrestors (standard delivery in China).
All generators are connected with a single bus-bar. An 11kV bus-bar PT panel is arranged for parallel operation. All 11kV H.V. panel adopt KYN28A-12 metal-enclosed removable switchgears, the switch for generator switchgear adopts VS1 vacuum circuit breaker (with truck), its rated current is 630A, and rated short-circuit breaking current is 25KA.
The generator bus-bar connects to one 11kV outgoing panel. The switch adopts VS1 vacuum circuit breaker (with truck), its rated current is 1600A, and rated short-circuit breaking current is 31.5KA.(optional)
 
Generator switchgear
The generator connects to the bus-bar by vacuum circuit breaker in the generator switchgear.
Major Components in generator switchgear:
1)            3 pole truck type DC/AC 220V electrically operated motor energized VS1 VCB
2)            Metering / Protection CT and PT
CT type: CT LZZBJ9-11 250/5A ith two windings for each phase
Two CTs are installed in the generator switchgear. One CT is for current and power measuring (phase A and C) and excitation adjusting (phase B); another is for 2301D load sharing controller.
PT type: one REL-11 11/�?. 0.1/�?. 0.1/3kV with two windings for each phase
One group of windings in potential transformers is star connected for measuring and protection system. Another group of windings is triangularly connected for single phase earthing protection.
3)            Digital integrated relay
ICBU-360 digital integrated relay is adopted for gen-set protection, which is used for alternator protection, switch control, monitoring, measuring and display.
The following functions and protection can be carried out on the relay:
-          Differential
-          Voltage locked over current
-          Reverse power
-          Over current
-          Single phase Earthing
-          Over 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
4)            Local / Remote control selector
5)            VCB ON/OFF
6)            DSSX25 kWh and kVarh meter
 Components in switchgear:
1)    3 pole truck type DC/AC 220V electrically operated motor energized VS1 VCB.
2)    Metering / Protection CT
CT type: CT LZZBJ9-11 1600/5A with two windings for each phase
One group for current difference protecting between transformer’s input and output; one for current protection and power measuring.
3)    Digital integrated relay
DMR-301P digital integrated protection relay is adopted for transformer protection, and its protection parameter and function are configurable. The relay can indicate all parameters and store operation and accident record for the running transformer.
The following protection can be carried out on the relay:
-          Differential current
-          Instant trip current
-          Over current
-          Over load
-          Gas
-          High Insulation oil temperature
-          High Insulation oil pressure
4)    Local / Remote control selector
5)    VCB ON/OFF indication
6)    DSSX25 kWh and kVarh meter
 
Potential transformer panel
Major Components in PT panel:
1)    Fixed PT installation truck with arrester.
2)    PT type: one REL-11 11/�?. 0.1/�?. 0.1/3kV with two windings for each phase
One group of winding in potential transformers is star connected for measuring and protection system. Another group of winding is triangularly connected for single phase earthing protection.
 
The scope of electrical system consists of the electrical equipments inside of main building. The Buyer takes responsibility to transmit power from the feed-out panel to user position.
 
4.11.2   L.V. system
The auxiliary equipments for generator include 4 cooling fan (5.5KWx4), 3 air compressor motors (5.5kWx3), 1 booster (17kWx1) and one DC power source panel (4kW).
The auxiliary equipments for power plant include 2 HFO pump motors (18.5KWx2), 2 DO pump motors (18.5KWx2), 1 HFO separator module (22kW), 4 boiler water feed pump motors (2.2kWx4) and one soft water pump motor (3kW).
The lighting and air conditioner system is about 30kW, all lighting equipments are considered during civil work.
The fire fighting system includes 2 fire-fighting pumps (22kWx2) 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 50kW).
 
4.11.2.1 L.V. power source for power plant
The electricity for the power plant is supplied by a 500KVA transformer from the 11kV bus-bar.
 
4.11.2.2 DC panel
The power supply of control plant, protection, signal, automatic device and trouble lighting adopts 200AH direct current electrical source system.
220/24V DC battery charger of suitable capacity along with Lead acid type rechargeable batteries (12 V DC) is used. Charger is fully automatic, with float and boost charging facility. One set of DC/DC transfer module with 60A capacity for 24V output.
Major Components in the DC panel
1)            Source inspect and change over module
2)            Chargers and booster module
3)            12V batteries and battery detect unit
4)            AC/DC ammeters, voltmeters
5)            LCD operation screen

Protections provided for Chargers

6)            Over load / short circuit / earth fault
7)            Over voltage
 
4., 11.2 &nb, sp;  Control system
DG
For each one generator, one control and operation panel and one local control desk are supplied.
Gen-set control and operation panel
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, and speed can be displayed on it.
Major Component in console
1)    Control PLC
2)    Speed Governor controller
3)    Automatic Voltage Regulator
4)    Engine Frequency Monitoring Unit
5)    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
6) Operation and indicators
Push buttons, change over switches
VCB engaged indication,
Engine start permission indication
Excitation change over switch
DG VCB ON/OFF
DG VCB Trip and alarm indication
Engine Id, ling/Rating&, lt;, /DIV>
Engine start
Engine normal and emergency stop
7) AVR
The integral 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, 25A
Trigger Type          Alternator exciter Remanence
Accuracy             ±1%
Am. Temp            -40~+60°C
Reactive sharing      Auto regulating
8)     T4500 auto synchronizer
SELCO T4500 auto synchronizer is designed for automatic synchronization between generator and bus-bar in a minimum of time by controlling the speed via the electric servomotor on the governor.
The T4500 measures the voltage across two phases on either side of the circuit breaker in order to obtain data on voltage, frequency and phase difference for closing the circuit breaker at exact phase accordance.
The synchronization function will become active when the difference between the bus voltage and the generator voltage is within limits. The voltage difference is selectable between 2% to 10%.
When the synchronization function is active, the T4500 will automatically adjust the speed of the generator through the governor in order to match the frequency to the bus-bar.
The T4500 will continuously adjust the generator speed until the frequency difference is within limits. When the voltage and frequency difference are within limits, the closing signal will be activated just before the next phase accordance, anticipating the circuit breaker make time. The T4500 compensates for this make time so that the circuit breaker will close exactly at zero phase.
Specifications for the T4500:
Circuit breaker operating time               20~200mS
Frequency difference                       0.1~1Hz
Voltage difference                         10%
Reference voltage                         110/100V with voltage matching
Operating Temp                           -20~+70°C
Contact rating                              AC: 380V, 2A, 250VA; DC: 110V, 2A, 100W
Auto synchronization system is adopted between generators and network and among generators. Manual synchronization system is supplied for standby.
9)            Load sharing
All generators can work in parallel; load can be equally shared among all generators automatically. Woodward programmable and configurable speed governor controller 2301D are adopted to control the engine, which can share or operate Gen-set in base load mode or isochronous mode.
Main functions on the control and operation panel:
-          Starting engine
-          Speedup
-          Speed-down
-          Generator switch ON/OFF
-          Voltage adjustment
-          Reactive power share
-          Synchronization
-          Voltage measuring changeover
-          Lube oil pressure
-          Water pressure
-          Voltage
-          Current
-          Frequency
-          Power
-          Excitation current
-          Speed
-          Alarm
 
Local Control Desk
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
 
Central control panel
A central control panel is installed in the control room, which is used for displaying signals for auxiliary equipments including oil storage level alarm, water level alarm, oil temperatures, steam pressure and others.
 
4.11.3    Protection system
4.11.4.1  Diesel engine
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
 
4.11.4.2   DG electricity system
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
 
4.11.4.3   11kV electrical system
One DMR301 digital integrated relay is installed on each 11kV-outgoing panel, the following functions can be carried out on the relay:
-          Over current
-          Instant current trip
-          Running record and failure store
-          Controlling switch on site or on remote mode


5. Main equipments specifications
5.1 Diesel engine:
 
Model
GN8320ZD12
Type
Inline, four-stroke, direct injection, turbocharged, and after cooled
Quantity
4 sets
Rated power
2647kw
Rated speed
600r/min
Bore/stroke
320/380mm
Starting method
Compressed air
Cooling system
Open water cooling
Dimension
5620×1620×2760mm
Weight
28000kg
Manufacturer
ND
Main parts of GN8320ZD12 Diesel Engine
a.     ABB turbocharger
b.    WOODWARD electrical governor
c.     GEA after cooler, lube oil cooler and radiator
d.    Flexible coupling
 
5.2 Alternator
Model
TFW2500
Type
Brush-less synchronous alternator
Quantity
4 sets
Rated power
3125KVA
Rated speed
600r/min
Rated voltage
11000V
Frequency
50HZ
Power factor
0.8 lagging
Insulation class
F/F
Excitation
AVR
Dimension
3480×2150×2150mm
Weight
18000kg
Manufacturer
ND
 
5.3 Heavy fuel oil centrifuge
Model
SJ30G-1S
Quantity
2set
Rating treatment L/h
4500
Centrifuge Temperature
90-98°C
Light phase output pressure: MPa
0.2MPa
Motor power KW
3P/400V/50Hz/11kw
Complete machine weight (kg)
1600
Dimension
1250X1200X1500
Material medium
Heavy fuel oil (180CST/50°C)
Manufacturer
ND
5.4 Common Circulating & Booster module
Model
CRGD4.0-6.0LP
Fuel feed capacity
4.0 m3/h
Fuel circulating capacity
6.0m3/h
Fuel supply pressure
0.6Mpa
Fuel feed pressure
0.6Mpa
Max. fuel temperature
135°C
Min. Fuel feed rate
50M3
Rated fuel temperature 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
17kW
Load
8kW
Dimension LxWxH
3500X1500X2100mm
Weight
2300kg
Manufacturer
ND
 
5.5 Exhaust Gas Boiler
Model
LFL80-0.7
Rate steam capacity:
700kg/H
Quantity
2 sets
Steam pressure:
7Bar
Steam temperature
170°C
Safe pressure
0.75Mpa
Heating area
80m2
Boiler back pressue
Max. 220pa
Waste gas inlet temperature
350°C
Waste gas outlet temperature
200°C
Overall dimensions LxWxH
1824x2310x5318mm
Weight
6000kg
Manufacturer
ND
5.6 Air compressor
Model
CZ-20/30F
Type
Single row vertical, differential piston two-stage compression, air cooled
Exhaust capacity
Min. 20m3/h
Quantity
3 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
ND
 
5.7 Air Bottle
Model
B500
Quantity
4 sets
Air inlet & outlet
33
Working pressure
2.94Mpa
Volume
500L
Overall dimensions
628x2305mm
Weight
468kg
Manufacturer
ND
 
5.8 S9-500/11/0.4 Power transformer
Type
S9-500/11/0.4
Rating
500KVA
Primary Volts
11KV
Secondary volts
0.4KV
Insulation level
Standard
Quantity
1 set
Manufacturer
ND
 
5.9 Cooling tower
type
GBL-100
Quantity
4 sets
Cooling capacity
100M3/H
Inlet water pressure
34 kpa
Temperature reduce
5~10°C
Fan power
5Kw
Net weight
1800kg
Manufacturer
ND
5.10 HFO unload station
Type
HFO58
Quantity
1 set
Capacity
58M3/h
Outlet pressure
0.28Mpa
Motor power
18.5Kwx2
Manufacturer
ND
 
5.11 Diesel oil unload station
Type
DO58
Quantity
1 set
Capacity
58M3/h
Outlet pressure
0.28Mpa
Motor power
18.5kWx2
Manufacturer
ND
5.12 Station batteries and battery charger panel
Model
PGD-7IV-180-220
AC input voltage
380Vac±20%
DC output voltage
24V, 220V
DC output current
40A
Storage battery capacity
75Ah
Accuracy of voltage regulation
Max. ±0.2%
Accuracy of current regulation
Max. ±0.2%
Ripple factor
Max. 0.1%
Power factor
Min. 0.93
Efficiency
Min. 95%
Noise
50dB
Dielectric strength
2000V 1 min without breakdown
Operation environment
Temperatur:-10 to 45°C, Relative humidity:not greater than 90% at 20±5°C
Interface
RS485, RS232 & RS422
High frequency rectifier module
Emerson HD22020 3pcs
PLC
SIEMENS S7-200
LCD display screen
HITECH PWS 5.7"
Rectifier module
Emerson HD2205 3pcs
Maintenance-free lead-acid battery
A400-180/12V 18 pcs
Overall dimensions (LxDxH)
800x800x2200mm 3pcs
Manufacturer
ND

Total price: $4,142,710 (FOB China)   Quotation code: 3020130703





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