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Contents
GENERAL ..................................................................................................................................4 MAIN DATA OF THE POWER PLANT......................................................................................................4 DERATING OF DG OUTPUT..................................................................................................................4 WATER REQUIREMENT........................................................................................................................5 QUALITY OF LIGHT FUEL OIL (LFO)..................................................................................................5 QUALITY OF HEAVY FUEL OIL (HFO)................................................................................................6 LUBE OIL CHARACTERISTICS...............................................................................................................7 CODES AND STANDARDS.....................................................................................................................7 . GENERAL LAYOUT.............................................................................................................8 MAIN DG BUILDING............................................................................................................................8 DG ROOM............................................................................................................................................8 AUXILIARY ROOM...............................................................................................................................8 SWITCHING ROOM...............................................................................................................................8 COOLING WATER STATION ..................................................................................................................8 TANK AREA.........................................................................................................................................8 HEAVY FUEL OIL TREATMENT STATION ..............................................................................................8 . DIESEL GENERATING SET ..................................................................................................9 SPECIFICATION OF DG SET..................................................................................................................9 MAIN DATA OF DIESEL ENGINE .........................................................................................................10 MAIN DATA OF GENERATOR..............................................................................................................11 PERFORMANCE OF DG SET................................................................................................................11 MECHANICAL AUXILIARY SYSTEM ............................................................................12
FUEL OIL SYSTEM..............................................................................................................................12 LUBE OIL SYSTEM .............................................................................................................................14 COOLING WATER SYSTEM .................................................................................................................16 COMPRESSED AIRSYSTEM ................................................................................................................17 AIR INTAKE/GAS EXHAUST SYSTEM .................................................................................................17 . ELECTRICAL CONTROL SYSTEM................................................................................18 ELECTRICAL EQUIPMENT ..................................................................................................................19 PRIMARY CABLING............................................................................................................................19
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SECONDARY CIRCUIT ........................................................................................................................21 DC SYSTEM.......................................................................................................................................22 PERFORMANCE DATA DETECTION .....................................................................................................22 MAIN ALARMS OF DG SETS ..............................................................................................................22 ENGINE CONTROL .............................................................................................................................23 AUXILIARIES CONTROL.....................................................................................................................23 FACTORY POWER SUPPLY .................................................................................................................23 . PROJECT AND SCOPE OF SUPPLY ...............................................................................24 BOUNDARY .......................................................................................................................................24 SCOPE OF SUPPLY..............................................................................................................................24
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General
The proposed stationary 37 x 5.5MW diesel power generating plant is for base load application and intended for electricity production operation in parallel with public supply system. The diesel engine is connected with the generator via flexible coupling. The fuel for DG sets can be either diesel oil or heavy fuel oil. The mechanical auxiliary equipment of the DG will be grouped into functional modules to facilitate installation and operation. Single bus design is used for its electrical design i.e. the power generated from 37 DG sets will be output to the bus. Power supply for the equipment in power plant itself will be taken from the bus through 13.8kV/0.4kV transformer. No additional standby generating sets are needed.
Derating of DG output
The output and fuel oil consumption rate are to be corrected according to relevant technical documents of the diesel engine manufacturer when the service condition on site does not conform to the standard conditions specified in ISO3046-1995.
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Water requirement
HT water and injector cooling water
Normal condition PH Total hardness (CaCO3 in ppm) Chlorinity Total salinity Density of acid ion ( SO24) Fe Silicon dioxide Residue on evaporation
Quality of Light Fuel Oil (LFO) Quality of Heavy Fuel Oil (HFO)
Viscosity, min. Viscosity, max. Density, max. (at 15 C) Conradson carbon res. max. Sulphur, max. Vanadium, max. Sodium, max. Ash, max. Water, max. Water before engine, max. Flash point, closed Pensky-Martens, min. Pour point, upper max. Aluminium + silicon, max. Total sediment potential, max. cSt at 40 cSt at 40 g/ml % mass % mass ppm % mass % Vol % Vol mg/kg % mass 2.8 14.0 0.92 3.0 2 100 0 0.05 0.30 0.2 60 6 25 0.1
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Fuel oil specification CIMAV 2003 BS MA-100 ISO F-RM Fuel-system related characterstic values mm2/s(cSt max. Viscosity(at 50) ) Viscosity(at 100) max. g/ml max. Density(at 15) Flash point min. Pour point(summer) max. Pour point(winter) max. Engine-related characteristic values Carbon residues(Conradon) % wt. Sulphur Ash max. Vanadium mg/kg
A30 A30
B30 M4 B30
D80 M5 E/F180
E/F18 M7 E/F180
H/k700 M9/H/K700
80 15 0.985
180 25 60
700 55
14 4
15/20
18/22 5 0.15
22 0.20 600
350
200/50 0
300/600
Water % vol. 0.5 0.8 1 Sediment(potential) % wt. 0.1 Supplementary characteristic values Aluminium and mg/kg silicon max. Asphalts % wt. Sodium mg/kg Cetance number of low-viscosity constituent minimum 35 Fuel free of admixtures not based on mineral oil, such as coal oils or vegetable oils; free of tar oil and lubricating oil(used oil)
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. General layout
This 37x 5.5 MW diesel power generating plant will occupy an area dividing into four sections i.e. main DG building, cooling water station, tank area and heavy fuel treatment station.
Main DG building
The main DG building consists of three rooms i.e. switching room, DG room and auxiliary room.
DG room
The elevation of the DG room is equipped with a 7 ton bridge crane for maintenance and lifting of components.
Auxiliary room
The auxiliary room is on the engine side of the DG room. Auxiliary equipment such as oil pumps, water pumps, heat exchangers, air compressors, air bottles and some pipes will be installed in the room and the air intake and gas exhaust pipes as well as HT water expansion tank will be installed at the top of the room.
Switching room
Switching room is located at the generator side of the DG room. There are specific rooms for high voltage, central control, switching gear and transformer.
Tank area
Fuel oil storage tanks in the tank area will be built together. Position for slag oil is reserved in the tank area. Transfer pumps for light diesel oil and heavy fuel oil will be installed inside the tank area.
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Specification of DG set
Type Rated power Rated voltage Rated current Number of pole pairs Power factor Rated frequency Rated speed Phase Excitation Dry Weight External dimension(LWH) THH5500/13800 5500 kW 13.8kV 288 A 4 0.8 (lagging) 50 Hz 750 r/min 3 phase brushless excitation 101 ton 11,045 x 3,365 x 4,850 mm
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Type Model N0. of cylinders Rotating direction Cylinder bore Stroke Swept volume Compression ratio Type of combustion chamber Injection method Starting method Max. continuous rating (MCR) Overload power (1h out of 12 h) Rated speed Mean effective pressure Max. explosion pressure Min. stable speed Firing speed Exhaust temp. at cyl. outlet Fuel oil consumption Lube oil consumption External dimension Weight (dry)
12V32/40 4 stroke, V-type, direct injection, gas turbo charging, air intercooled 12 clockwise (view from PTO) 320 mm 400 mm 32.17 dm3 14.5/1 direct injection mechanical drive, single body injection pump compressed air starting 5500kW 6050kW 750 r/min 2.49MPa 19.00.29MPa 250 r/min 80 r/min 51050 (difference between any two cylinders 50) 185+5 g/kw.h Lev= 42700kj/kg 1.0 g/kw.h 6,915 x 3,140 x 4,100 mmLWH 64 ton
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Performance of DG set
Steady state voltage deviation Transient voltage regulation Voltage recovery time Voltage fluctuation No-load voltage setting range within 2.5% +20% -15% 1.5 second 1% 95% --105% rated voltage
The distortion rate of sinusoidal waveform of line voltage at no-load rated voltage. 5% Steady state frequency deviation Transient frequency deviation Frequency recovery time Frequency fluctuation 5% 10% 7 second 1%
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1. Fuel oil storage system Diesel oil transfer pumps are to be equipped to facilitate unloading of fuel oils. The diesel oil transfer pump is for delivering diesel oil to the diesel oil daily tank for starting, running and stop operations of the DG sets. Main facilities in the fuel oil storage system are Strainer LFO transfer pump LFO delivery pump LFO daily tank LFO storage tank Light fuel oil daily tanks are all equipped with level indicator and level switches for alarm and control.
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2. FO feeding unit The function of the feeding pump unit is to pump fuel oil from the storage tank to the day tank. It provides the engine with filtered fuel of correct quantity and pressure. It consists of feeding pump, fine filter, flow meter, booster pump, and control system. Its function is to supply fuel oil to diesel engine at an appropriate viscosity, pressure, flow and cleanness. Transfer pumps and other components are built on a steel frame, which forms one compact unit. Main facilities are as follows: Electric feeding pump Electric booster pump Duplex strainer Duplex fine filter Pressure drop indication and alarm Control panel Connecting pipe, valve, flanges Steel base frame
3. Heavy fuel oil separating unit The unit consists of centrifugal separators and feed pump, strainer and heater. Its function is to separate water content and particles in the heavy fuel oil which are hazardous to engine. Its working procedure is as follows: First heat up the HFO coming from HFO storage tank to a temperature suitable for separation. Then separate the HFO according to its nature through appropriate gravity disk. HFO after the treatment will be delivered to HFO daily tank. The slag and contaminated water will be drained to slag collector. Switch on the slag oil pump to drain it to slag oil tank when the slag in the collector accumulates to certain amount.
4. HFO feeding unit It consists of feeding pump, fine filter, flow meter, blending device, booster pump, heater and viscosity-temperature control system. Its function is to supply fuel oil to diesel engine at an appropriate viscosity, pressure, flow and cleanness and realize the switch over between diesel oil and HFO. Every two DG sets share one unit. Its working procedure is as follows: Measure the temperature and viscosity of the HFO coming from HFO daily tank through thermal transmitter and viscometer. Heat up the HFO automatically to the set temperature, at which the viscosity of HFO can ensure the normal operation of the diesel engine. Finally feed the HFO after fine filtration to DG sets though the booster pump.
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Main facilities are as follows: Electric feeding pump Electric booster pump Degas blending tank Duplex strainer Fuel oil heater Temperature-viscosity control device Duplex fine filter Pressure drop indication and alarm Control panel Connecting pipe, valve, flanges Steel base frame
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1. Main lube oil circuit of diesel engine The main lube oil system of the diesel engine is to supply lube oil for moving parts of the engine. Main lube oil pump delivers lube oil from lube oil tank to engine inlet through lube oil fine filter. Lube oil cooler and three-way thermostatic valve ensure the temperature of the lube oil at engine inlet. Main facilities are as listed below: Electric lube oil delivery pump Lube oil cooler Lube oil fine filter Thermostatic valve Control panel Connecting pipes, valves, flanges Steel base frame 2. Lube oil separating unit The function of lube oil separating unit is to separate the water content and particles in the main lubricating system at fixed intervals. Two DG sets share one unit. Lube oil of two DG sets can be separated during operation of DG sets. Each lube oil separating unit consists of the following facilities: Lube oil separator Filter Heater Slag oil tank Control panel Connecting pipe, valve, flange Steel base frame
3. Lube oil storage system For storage, compensation and refill of lube oil for the Plant. Lube oil storage tank Lube oil delivery pump Engine circulating lube oil tank Waste oil tank
4. Emergency lube oil system For supplying necessary lube oil for stop of engine when accidents such as loss of power etc. Main facilities: Gravity oil tank Automatic oil feeding device
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1.
LT water circulating system consists of pump station and cooling tower. Its function is to cool air cooler, lube oil cooler, HT water cooler and injector cooler. Main facilities are as follows: LT circulating pump Cooling tower
2. HT water system HT water system is to cool cylinder liners, cylinder heads and turbocharger consisting of cooling unit and expansion tank. Main facilities included in the cooling unit are: HT water pump Thermostatic valve Connecting pipe, valve, flange HT water cooler Control panel Steel base frame
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3. Injector cooling water system Main facilities are: Injector cooling water pump Injector cooler Thermostatic valve Cooling water tank Control panel Connecting pipe, valve, flange Steel base frame
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Electrical equipment
No. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20
Designation Local control panel Generator control cubicle PT cubicle CT cubicle Generator outgoing switch cubicle Neutral earthing cubicle Generator protection cubicle DC24V panel DC110V panel Common pump control panel 0.4KV control cubicle 0.4KV switch cubicle Factory power control cubicles 0.4KV compensation panel Transformer 13.8KV/0.4KV 1250KVA 0.4KV outgoing cubicles Transformer incoming switchgear cubicle Busbar PT cubicle 13.8KV outgoing cubicle
Primary cabling The primary cabling of the Plant is 13.8KV single bus. The output of 37 DG sets are all connected to 13.8KV bus. The final outgoing circuit and outgoing way shall be decided after confirmation with the customer. In the 13.8kV bus of primary cabling diagram, the factory power supply is taken from the 13.8kV bus via 13.8kV/0.4kV factory transformer. The 13.8KV electrical cubicles for primary cabling are XN2 fixed switch cubicle. The main equipment includes generator output cubicles, PT cubicles, neutral earthing cubicles, CT cubicles, outgoing switch cubicle and factory power transformer switch cubicle.
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1 . Generator output cubicles Automatic and manual breaker close and trip switch Differential protection current signal Generator neutral earthing fault protection Circuit-breaker and motor heater interlock with fan motor. Stop the generator heater when close the generator outgoing circuit-breaker and start the generator ventilation motor simultaneously. Stop the motor when the circuit-breaker trip. Enable the manual and electrical operation of close and trip.
2. Neutral earthing cubicles Supply the differential protection circuit current signal Supply voltage signal for exciting automatic regulator Supply current signal for zero sequence protection circuit
3. PT cubicle Supply voltage signal for active power, reactive power, three-phase current, power factor and frequency measure. Supply generator protection voltage signal
4. CT cubicle Supply current signal for excition regulation and active and reactive power meter Supply generator protection voltage signal 5. Outgoing cubicle Supply outgoing circuit for power users
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Secondary circuit
The secondary system of the Plant includes mainly he control, protection and monitoring system which uses normal magnetic relays. Generator protection and the protection of transformer and wirings are realized through integrated protection devices. The secondary protection devices are integrated into one control panel, which are installed in the control room. DG sets and 13.8KV busbar use the manual synchronizer to realize the grid paralleling. The voltage and frequency regulation for grid paralleling is realized through central control table. DG sets protection in secondary system contains the following: - Differential protection - Reverse power protection - Overload protection - Over voltage protection - Combined under voltage and over current protection - Neutral earthing protection - Quick trip and over current protection for 13.8KV busbar outgoing switch The electrical data of all DG sets are gathered at the central control table and displayed, recorded and printed by computer.
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DC system
The DC power system of the Plant has two types of load current i.e. DC24V 20AH and DC110V 80AH. The diesel engine and related instruments use DC24V. DC110V is used for main control room and other Plant control systems, protection and communication, and emergency lighting system.
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Pressure - Lube oil pressure at engine inlet - Lube oil pressure at turbo charger inlet - Fuel oil pressure at engine inlet - Pressure in over speed protection air receiver Safety stop - Over speed protection - Low lube oil pressure at engine inlet - High HT water temp. At engine outlet
Engine control
There are two control modes for engine i.e. local control and central control, which can be selected by the local switch. The local control can facilitate maintenance and inspection works. Besides the instruments for easy monitoring, the local control panel also contains control elements for starting, stop, emergency stop and speed regulation, which enable the start, stop, over speed protection, emergency stop and local/central switchover operations. Each DG set is equipped with one LCP. Part of performance data such as engine speed, start air pressure, engine lube oil pressure at engine inlet are monitored by the special instruments
Auxiliaries control
Control of auxiliaries of engine includes: Fuel oil pump HT water pump Injector cooling water pump Turning gear motor Generator ventilation motor (half pipe type ) Lube oil pump LT water circulating pump Rocker arm lube oil pump Start air compressor Generator heater
The start and stop of most auxiliary pumps are controlled by the units in this system. Auxiliary unit shall have its own local control box. Some auxiliaries are controlled in distributing room.5 DG sets share one panel.
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Boundary
The interface between the 13.8kV bus and the city grid is the outer side of the outgoing bus switch. The water supply will come from the city water supply system. The interface is at 1 meter outside of the territory of the Plant. The drain water of the Plant will go to the infiltration basin outside of the Plant. The interface between the communication system and the city communication network is at 1 meter outside of the territory of the Plant
Scope of supply
Item No. A A.1 A.1.1 A.1.2 A.1.3 A.1.4 A.1.5 A.1.6 A.1.7 A.1.8 A.1.9 A.1.10 A.1.11 A.1.12 A.1.13 A.1.14 A.1.15 A.1.16 B B.1 B.2 B.3 B.4 B.5 Scope Factory CT
Description DIESEL GENERATING SET Diesel Engine 12V32/40 6000kw, 750 r/min Turbocharger Air Cooler Governor Fuel Injection Pumps Instrumentation Protection devices Junction box Engine Common base Flywheel Flywheel turning device Leak Oil Tank Wedges and anchor bolts Maintenance platforms Alternator with AVR, 6875kva, 50Hz, 13.8kv Engine Special Tools Commissioning Spare Parts LIGHT FUEL OIL (LFO) SYSTEM LFO Storage Tank Level Indicator for LFO Storage tank LFO Unloading Pumps Strainers for LFO Unloading Pumps LFO Day Tank
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Item No. B.6 B.7 B.8 B.9 B.10 B.11 B.12 B.13 B.14 B.15 B.16 C C.1 C.2 C.3 C.4 C.5 C.6 C.7 C.8 C.9 C.10 C.11 C.12 C.13 C.14 C.15 C.16 C.17 C.18 C.19 C.20 C.21 C.22 C.23 C.24 C.25 C.26 C.27 C.28
Description Level Switch LFO Day tank Level Switch LFO Day tank Level Gauge LFO Day tank LFO Transfer Pumps Strainers for LFO Transfer Pumps LFO Flow meter Strainers for LFO Flow meter LFO Filter Unit Piping Valves Gauges 1 HEAVY FUEL OIL (HFO) SYSTEM HFO Storage Tank Level Indicator for HFO Storage Tank HFO Unloading Pumps Strainers for HFO Unloading Pumps HFO Storage Tank Transfer Pumps Strainers for HFO Transfer Pumps HFO Settling Tank Level Switch for HFO Settling Tank Level Switch for HFO Settling Tank Level Indicator for HFO Settling Tank HFO Service Tank Level Switch for HFO Service Tank Level Switch for HFO Service Tank Level Indicator for HFO Service Tank HFO (Centrifuge) Separator unit HFO Conditioning Unit HFO Drain Tank Transfer Pumps for HFO Drain Tank Level Switch for HFO Drain Tank HFO/LO Sludge Tank Transfer Pumps for HFO/LO Sludge Tank Level Switch for HFO/LO Sludge Tank Sludge Storage Tank Transfer Pumps for Sludge Storage Tank Sludge Recovery Pond (Concrete made) Transfer Pumps for Sludge Recovery Pond Transfer Pumps for Sludge Pit Level Switch for HFO/LO Sludge Tank
Scope Factory CT
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Item No. C.29 C.30 C.31 D D.1 D.2 D.3 D.4 D.5 D.6 D.7 D.8 D.9 D.10 D.11 D.12 D.13 D.14 D.15 D.16 E E.1 E.2 E.3 E.4 E.5 E.6 E.7 E.8 F F.1 F.2 F.3 F.4 F.5 F.6 F.7 F.8 F.9 F.10
Description Piping Valves Gauges and Thermometers LUBRICATING OIL SYSTEM Lube Oil Storage Tank Lube Oil Unloading Pumps Lube Oil Transfer Pumps Lube Oil Sump Tank Level Switch for LO Sump Tank Lube Oil (Centrifuge) Separator unit Lube Oil Cooler Prelubricating oil Pumps Lube Oil Circulation Pumps Lube Oil Filter Lube Oil Filter for LO Transfer Pump Thermostatic 3-way valve Lube Oil Regulating Valve Piping Valves Gauges and Thermometers COMPRESSED AIR SYSTEM Starting Air Compressor Starting Air Receiver Air Reducing Valve Unit Control Air header Control Box Piping Valves Gauges RAW WATER COOLING SYSTEM Cooling Tower/ radiator cooling tower Raw Water Circulation Pumps Raw Water Storage Tank Level Switch for RW Storage Tank Water Treatment System module Treated Water Storage Tank Level Switch for Treated Water Storage Tank Treated Water Transfer Pumps(to Engine auxiliaries) Piping Valves
Scope Factory CT
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Item No. F.11 G G.1 G.2 G.3 G.4 G.5 G.6 G.7 G.8 G.9 H H.1 H.2 H.3 H.4 H.5 I I.1 I.2 I.3 J K K.1 K.2 K.3 K.4 K.5 K.6 K.7 K.8 K.9 K.11 K.12 K.13 K.14 L L.1
Scope Description Gauges and Thermometers JACKET WATER COOLING SYSTEM Jacket Water Circulation Pumps Jacket Water Cooler JW Thermostatic 3-way valve JW Expansion Tank Level Switch for Expansion Tank Nozzle Oil cooling pump Piping Valves Gauges and Thermometers EXHAUST GAS SYSTEM Exhaust Gas Silencer Expansion Bellows (at Turbocharger) Expansion Bellows (at Silencer) Chimney of Smokestack Piping/Ducting INTAKE AIR SYSTEM Air intake filter Input Air expansion joint Piping/Ducting DIESEL ENGINE CONTROL PANEL GENERATOR & ELECTRICAL Generator Control Pane Station Transformer Control Pane Outgoing Feeder Control Pane Generator CB Pane Bus PT Panel Station Transformer CB Panel Outgoing feeder CB pane LV General Input CB Panel LV CB Panel Auxiliary Equipment Control Pane 110/24V DC System All Transformers Power and Control Cable GENERAL EQUIPMENT Maintenance Overhead Crane SXD: To be supplied by The Factory CT: To be supplied by Customer Factory C T
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