2013-02-23

81 MW HFO Power Plant with 5 x Wartsila 18V46 Diesel Generators

Power plant nominal output at the site condion is 81300 kWe at generator poles with each generating
set contributing 16260 kWe. The plant is designed for operation on heavy fuel oil with light fuel oil
as standby/startup fuel. The operation, control and monitoring of the power plant carried out via a
central control panel and the Wartsila Operator Interface System (WOIS). The plant started operation
in year 2002 , was in operation till end of 2012 and is still installed and can be tested.

The plant consists of five (5) diesel generators each with a rating of 17500 kW/unit. The guaranteed
current site output is 16260 kWe/unit for a design condition of 32° Centigrade ambient temperature,
770 m altitude & 40% Relative Humidity (RH). Light diesel oil (LDO) is used as start-up and shut
down fuel and heavy furnace oil is used as load bearing fuel. Two HFO bulk storage tanks of
capacity 6500 m3, one LDO tank of 500 m3, two HFO buffer tanks (200 m3) and two HFO day
tanks (150 m3) are provided with four HFO separators. Three heat recovery steam generators of
capacity 1500 kg/hour are used for generating steam at 7-bar pressure and 170°Centigrade required
for heat tracing/ heating fuel oil/ lube oil. One LDO fired boiler of capacity 3000 kg/h is also
provided for meeting the steam requirement during black start-up or stand-by period of the plant. De-
mineralized (DM) water is used for cooling the primary circuit (engine cylinders). Raw
water/clarified raw water is used in secondary circuit. Cooling tower with six cells is provided for
cooling the heated raw water in secondary circuit.

The electric power is generated at 11 kV/50 Hz using air-cooled ABB made brushless syncronous
alternators. The generators are interconnected at the 11 kV SF6 switchgear with bus sectionalizing.
The power from 11 kV is fed to the grid at 110 kV using two 58 MVA step-up transformers. The
step-up transformers are rated same even though the normal loading on one transformer will be about
66% to ensure that in the event of outage of one transformer at least power from three generators can
be fed to the grid under these conditions. The 110 kV switchyard is bussed without bus sectionalizer
and the two outgoing lines ultimately feed power to 220/110 kV. The auxiliary power for the plant is
derived from 2 nos. 2 MVA service transformers. One 2 MVA service transformer can cater to the
entire auxiliary power requirement of the plant.

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23

Diesel Generating Units

The plant has five Wartsila 18V46 engines coupled with ABB AMG 1600SS12 DSEB alternators.
The engine is a 4 stroke, direct injection, turbocharged and intercooled design with 18 number of
cylinders arranged in two banks in ‘V’ type giving an nominal output of 17500 kWe. Direction of
rotation facing flywheel is clockwise with a speed of 500 rpm. Each cylinder has two inlet & outlet
valves with 460mm bore and 580 mm stroke. Each engine houses two turbochargers each in one

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23
bank and one turning gear, oil mist detector, charge air cooler, crank case relief valve, governor,
flexible coupling connecting to alternator.

Alternator:

Generator is self-cooled, 3 phase, brushless synchronous two bearing type with an output of 19300
kVA at 11kV 50Hz generating voltage & frequency, rotating at a nominal speed of 500 rpm (600
rpm over speed). Generator has insulation class-F and Protection IP23. Excitation Power is supplied
by exciter mounted in the generator through a diode bridge and control power for exciter is supplied
by an Automatic Voltage Regulator (AVR).

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23

Fuel Oil System

The main fuel used in Engines is HFO. Fuel is unloaded into large 6500 m3 HFO storage tank with
special undoading pumps. LFO is also received and pumped in to 500 m3 storage tank by an
independent pump. Oil from the HFO tanks is transferred to the settling or to the buffer tank where
the oil is allowed to settle so that any moisture content or heavy particles settle down due to density
difference. Oil from here is further pumped by the HFO separator feed pump to the separator where
the oil purification is done by the centrifuge process. Oil from the separator goes to the day tank.
Through feed pumps in the feeder unit oil is transferred from the day tank to the booster unit where
the oil is heated to the requisite temperature for feeding into the engine, filtered & any gaseous
component in oil is vented out in the de-aeration tank in the booster unit itself. From the booster unit
oil is pumped to the fuel oil unit where it is further filtered & pressurized by the pump, which then is
fed into the engines for combustion. The oil that returns from the engine is then collected in the
return fuel unit tank which is then pumped by the return fuel pump to the inlet fuel line.

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23

During starting & stopping of the engines, LFO can be directly pumped from the LFO tank to the
fuel oil unit where changeover of HFO into LFO is done through a quick closing valve. This
operation can also be done from the booster unit through the change over valve.

Oil flow from unloading point to the feeder unit

Oil flow from feeder unit to the engine

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23

Engine Lubrication System:

Lube oil in engine is basically used for lubricating purpose, cooling of dynamic parts & as well as for
cleansing. The engine is wet sump type i.e., the sump is directly fitted to the engine at its bottom and
the capacity of the sump is 16 000 liters. Lube oil from the engine is pumped out through an engine
driven pump which forces lube oil to the lube oil PHE (Plate Heat Exchanger) where the lube oil is
cooled with the engine LT water and then goes to a thermostat that regulates the inlet temperature.
From the thermostat the lube oil goes to the auto filter, the fine duplex filter and back to the engine.

A pre-lube oil pump is connected in parallel to the lube oil circuit. Apart from this circuit, there is a
circuit for cleaning of lube oil, wherein the oil is pumped out form the engine sump through a feed
pump into a centrifucal purification separator, where the carbon & moisture content if any from the
lube oil are removed and the lube oil is fed feed back to the engine sump.

Lube Oil system flow diagram:

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23

The Air System (Start Air and Instrument Air)

During start-up, all engines require air at a minimum pressure 18 Bar for initial cranking. The start
air system comprises of two 42KW main start air compressors, two 1.5KW INGERSOLL RAND
Compressors, four air bottles of each 3 m3 storage capacity located within the engine room. In
addition, there is an air compressor with a capacity of 18KW, 8.6 Bar for instrument/control air
supply located in Fuel Oil Pump House (FOPH).

Air system flow diagram:

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221
 2013-02-23
Cooling Water System:
Plant has two raw water reservoirs with storage capacity of 5000 M3 each. Raw water pump house
has two 15 kW / 2084 LPM raw water make-up pumps which pump the water from water reservoirs
to cooling tower sump through sand filters (2 Nos) of capacity 64 m3 /h. Cooling tower sump has an
electro-pneumatic level controller to maintain the sump level. Cooling tower has six individual
towers and a common sump. Each tower has a 75 kW/152.7 LPS capacity cooling tower pump to
circulate the water from cooling tower sump to the Raw Water Plat Heat Exchanger’s (PHE) of each
of all five engines located in DG hall and sixth tower/pump serving as a stand-by. The cooling
system of the engine is divided into High Temperature (HT) and Low Temperature (LT) circulation
system within the engine. Each system is fitted with its own circulation pump driven by the engine.
LT mainly serves for Charge Air (Air for Combustion inside Cylinder) and lube oil cooling whereas
HT for remaining other parts of engines. After carrying the heat from the various parts of engines
both LT/HT water are cooled in raw water PHE’s of each individual engines. This system also
includes two maintenance water tanks of around 15m3 storage capacity each. These maintenance
tanks store DM water which is used to make-up the losses of HT/LT water during normal operation.
During maintenance activities same maintenance tanks acts as buffer's to store HT/LT water drained
from the engines

Address: Iiluodontie 9 A 117, 00980 Helsinki, Finland

Telephone: +358-50- 374 6777
E-mail: jade.trading@jade.inet.fi
VAT Number: FI21175221