• 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
  • 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
  • 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
  • 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
  • 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
  • 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set

1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set

Type: Self-Starting Diesel Generator
Installation Method: Fixed
Stroke: Six Stroke
Cooling Method: Water Cooling
Output Type: AC Three Phase
Speed: Low Speed
Customization:

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Rating: 5.0/5
Manufacturer/Factory, Trading Company, Group Corporation

Basic Info.

Model NO.
GF
Conditions of Use
Land Use
Usage
Common Units, Standby Unit, Emergency Crew
Landuse Type of Unit
Low Noise Automation Type
Excitation Mode
AC Rotating Exciter
Transport Package
Wooden
Specification
400V/6KV/11KV
Trademark
HEMG
Origin
China
Production Capacity
100

Product Description

1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set
Technical specification of 2.25 MW Diesel Generator Set for power plant from HEMG China
2.1 CLIMATIC CONDITIONS
 
2.1.1 ISO Conditions
 
.   Air temp. to turbocharger inlet       27 deg. C
.   Atmospheric pressure                    750 mm Hg
.   Relative humidity                    60 %
.   Water temp. at charge air cooler inlet 27 deg. C
 
2.1.2 Site Conditions (Assumed)
 
.   Air temp. to turbocharger inlet     50 deg. C
.   Altitude                                      200 m above sea level
.   Relative humidity                    60 %
.   Water temp. at Cooling tower outlet  32 deg. C
 
2.2 Rating of the D.G.set 
 
2.2.1 Under above mentioned site conditions
       ---------------------------------------------
                 Rating at   Alternator Rating at
                 Engine      efficiency alternator
                 Crankshaft             terminal (MCR)
                    KWm       ( % )     KWe   KVA
(0.8 pf)
  ---------------------------------------------
 
Nominal   2500         90.7      2265   2835
     Running   
       
-----------------------------------------------
 
 


 
3   DIESEL ENGINE
 
3.1 TECHNICAL DATA
 
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, single
                           acting, direct   
                           injection/turbocharged
                charge air cooled
 
.  Rotational speed           600 RPM
 
.  Mean effective pressure       20.5 Bar
    at rated power & speed
 
.  Mean piston speed             7.6 m/sec.
 
.  Rotation as seen from      Clockwise
           coupling side.
 
.  Swept volume per cylinder     30.5  litres
  
.  Compression ratio             13:1
 
.  Avg max. combustion pressure   130 bar
    (at rated power/speed)
 
 
 
 
 
 
3.2 Power rating
 
3.2.1 Rated power under ISO Conditions mentioned in       2.1.1
.  Maximum continuous rating (MCR)      3400 HP
   at engine crankshaft
.  Corresponding rotational speed  600  RPM
 
 
 
3.2.2  Under the following limiting ambient conditions :
 
. Air temp. at turbocharger inlet    45 deg. C
. Water temp. at charge air cooler inlet32 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.
 
 
3.2.3     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
 
         Base load %     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. 


 
 
 
 
3.3  FUEL AND LUBE OIL
 
3.3.1 Fuel
 
Each of the engine offered should be suitable for operation on Diesel or Fuel with max viscosity 180 cst at 50 deg.C.)
 
        Fuel consumption:
 
The hourly rate of fuel consumption per Kwh delivered at the crankshaft flange at rated power & speed (after running in of the engine & for engine with driven raw water, fresh water & lube oil pumps ) is     200 g/Kwh,   when  engine operates at Maximum Continuous Rating (MCR).
 
FUEL CONSUMPTION (with 3 driven pumps)
====================================================
                      G8300ZD8      Consumption at                  
         (600 RPM)           engine Cr.shaft
g/Kwh
====================================================
          100% Load 200
      
SITE   -----------------------------------------------
                75% Load       205.00          
CONDITION -------------------------------------------
          50% Load       214.00         
====================================================
 
The values are subject to a 3% tolerance .
 
 
 
 
 
 
 
 
 


3.3.2 Lubricating Oil:
 
Oil sump capacity (liter)
 
The engine is equipped with a dry sump attached to the bottom of the crankcase. The lube oil for the engine is stored in a separate tank positioned away from the engine. This arrangement offers much more reliability than the wet sump arrangement & also increases the time between oil changes.
 
The total oil capacity of this lube oil tank is 2000 liters.
 
Lube oil consumption
 
The average lube oil consumption is 1 gm/kwh          (+/- 0.2 gm/kwh) at MCR at crankshaft for a well-run engine.
 
Continuous centrifuging is essential for lube oil when operating on Furnace Oil. 


 
3.4 SCOPE OF SUPPLY (STD)
 
3.4.1 Starting air circuit
 
3.4.1.1  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
 
3.4.1.2  Equipment delivered loose:
 
-   One air compressor air
-   One air bottle 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.
 
 
3.4.2 Lube Oil Circuit:
 
3.4.2.1  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.
 
3.4.2.2  Equipment delivered loose:
-    One tank for lube oil (2000 ltrs capacity) with interconnections to the engine
-    One electric motor driven lube oil-priming pump (option)
-   One manual lube oil-priming pump
-   One lube oil cooler
-    One centrifugal lube oil filter (FLL75 bypass type)
 
3.4.3 Cooling Water Circuit
 
The engine cooling is achieved by close cooling water circuit.
 
 
A) Close Loop circuit:
 
Drawn by the water pump from the radiator, the cooling water flows to the air 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. Between the inlet water main pipe and the outlet water main pipe there is a thermostatic valve with a sensor at the engine outlet water main pipe, which by-passes part of the outlet water to the inlet of the water pump to keep the water temperature to be not too low. Finally the water is cooled in the cooling tower.
 
 
3.4.3.1 Equipment fitted on the engine:
-   One electrical water pump
-    One water thermostatic valve
-   One water-cooling tower including fan
 
  
3.4.4 Fuel Circuit (Additional equipments used for  HFO are not in our scope)
 
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 deg.C and the HFO (Heavy Fuel Oil) is heated to the required temperature, the fuel can be changed from DO to HFO through a 3-way fuel valve.
 
3.4.4.1  Equipment fitted on the engine: (the final design should have the data of the viscosity o HFO in order to adjust the injection set )
 
-   Individual fuel injection pump for each cylinder  with fuel rack & linkages (for DO and  HFO).
-   Individual injector fitted on each cylinder head (for DO and HFO).
-   High-pressure injection pipes (for DO and HFO).
-   Main fuel rails for feeding and return (for DO and HFO).
-   High-pressure pipe connection for each cylinder (for DO and HFO).
 
 
 
 
3.4.4.2  Equipment delivered loose (equipments used for HFO  not in our scope ):
 
1) Two HFO separator (one for working, one for standby)
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 HFO;
One flow meter for HFO;
One 3 way fuel changeover valve;
One viscosimeter & 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;
- Complete interconnecting piping with flanges, fasteners, valves, non-return valves, bosses,    supports, etc   as necessary up to Day Tank.
 
 
 
3.4.5     Air intake & Exhaust system
 
3.4.5.1  Equipment fitted on the engine:
 
-   Lagged set of exhaust manifold with expansion   bellows
-   One turbocharger.
-   Exhaust outlet connection with expansion bellow.
 
3.4.5.2  Equipment delivered loose:
 
-   One air filtration system with air ducting
-   Exhaust ducting with necessary expansion bellows
-   One exhaust silencer
-   Insulation /lagging/cladding for exhaust ducting                                 
 
 
 
3.4.7 Control and measuring instrument:
 
3.4.7.1 Equipment fitted on the engine:
 
-   One type hydraulic governor.
-   One servo booster with piping for governor
-   Exhaust gas pyrometric system with thermocouple for each cylinder for turbine inlet & turbine outlet with pyrometric duct.
-   One engine barring arrangement (manual) with   safety arrangement for detecting engaged barring                   gear.
-   Arrangement for manual stopping of the engine with safety arrangement for detecting locked hand                   stop control.
 
Note: All electrical equipments installed on the engine are electrically wired up to one or more terminal strips attached to the common base frame. Connections for remote pressure detection are also grouped together on   the base frame.
 
 
 
 
 
 
3.4.8 Miscellaneous equipments.
 
3.4.8.1 Equipment fitted on engine:
 
-   Individual cylinder head for each cylinder, each containing two inlet and two exhaust valves   (with valve rotators).
-   4 nos of explosion relief valves on crankcase.
-   One flywheel & coupling arrangement with necessary fasteners.
-   One common base frame for engine & alternator   with coupling guard, fasteners, anchor bolt etc.
 
NOTE
The system is designed for max 180 cst fuel at 50 degree C. If fuel of higher cst is to be used, then please furnish the specifications of the fuel for proper designing of the system. In this case there will be change in certain auxiliary equipment specifications and a corresponding increase in price.
 
 
 
4. Complete electrical system includes
 
1)              Alternator
2)              Control Panel for Generator
3)              Operation Panel for Generator
4)              Local control desk
5)              Air Circuit Breaker panel
6)              Battery Charger and Batteries (24V/220VDC)
7)              Control panel for gen-set auxiliaries
 
1.  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                        2800 KVA
- Power factor                          0.8 lag
- Max. Alternator output at site               2265 KW
- Duty                             Continuous
- Rated speed                         600 RPM
- Output voltage                      11000 V
- Efficiency at 100% load and 0.8 PF            90.7 %
- Direction of rotation                     anticlockwise
- 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                           Brush-less, self excited
- Connection                          Star
 
NOTE
Alternator design considers harmonics in load.
2.  Control Panel For Generator & Operation Panel For Generator

 
2.1   Function
Control Panel and Operation Panel provide necessary Monitoring, Control and Protection functions for the DG set. It is located in the DG control room.
 
 
 
 
 
2.2   Major Components
1)              Programmable Logic Controller (PLC)
2)              Generator Protection relays
3)              Automatic Voltage Regulator
4)              Meters, indicators, hour counters
5)              Push buttons, selector switches
6)              Engine Frequency Monitoring Unit
 
2.3   Metering Devices
7)              Analog Engine RPM meter
8)              Ammeters (3 nos.)
9)              Voltmeter with selector switch
10)            Frequency meter
11)            PF meter
12)           Analog Excitation fundamental ammeter
13)           Analog Excitation harmonics ammeter
14)          Counter for running hours
 
2.4   Generator Protections
15)         Voltage controlled over current
16)         Under / Over voltage
17)         Under / Over frequency
18)         Earth fault
19)         Very high Alternator bearing temperature
20)         Reverse power
21)         Field failure
22)         Master trip
 
 
 
 
2.5   Status Indications
23)         Low lube oil priming pressure
24)         Breaker engaged
25)         Engine start permission
26)         Unit ready for excitation
27)         PLC failure
28)         Ready for excitation
29)         DG breaker ON
30)         DG breaker OFF
31)         DG breaker Tripped
 

2.6   Alarm Indications

32)         Low lube oil pressure
33)         Low water pressure
34)         Low fuel pressure (in booster control box)
35)         Low start air pressure
36)         High lube oil temperature
37)         High water temperature engine inlet
38)         High fuel temperature engine inlet (in booster control box)
39)         Alternator bearing temperature high
 

2.7   Trip Indications

40)         Very low lube oil pressure
41)         Very high lube oil temperature
42)         Very high water engine outlet temperature
43)         Engine over speed
44)         Emergency stop
45)         Speed sensing failure
46)         Alternator fault
47)         Under / over voltage
48)         Under / over frequency
49)         Voltage controlled over current
50)         Earth fault
 

2.8   Controls possible

- Engine speed raise/low
- Engine start  
- Engine normal and emergency stop 
51)         Excitation ON / OFF
52)         Excitation Raise / Low
53)         Excitation adjust
54)         Breaker control
 
 
- Fault indication
- Lamp test
- Reset
 

3.   Local Control Desk

3.1   Function

Local Control Desk (LCD) is provided for monitoring Pressure and Temperature parameters of the engine. Also starting, stopping and speed control of engine is possible in local Control operation mode. It is located near the engine.

3.2   Major Component

55)         Pressure gauges, switches
56)         Temperature indicators or scanner
57)         Scanner for Engine exhaust temperatures
58)         Push buttons, indicating lamps, selector switches
59)         Flasher
 

3.3   Pressure Gauges

60)         Lube oil filter inlet pressure
61)         Lube oil filter outlet pressure
62)         Lube oil cylinder head inlet pressure
-  Fuel engine inlet pressure
-  Starting air pressure
-  Water engine inlet pressure
 
3.4   Pressure Switches
63)         Lube oil engine inlet pressure

3.5   Temperature Indicators / scanner

64)         Lube oil engine inlet temperature
65)         Lube oil engine outlet temperature
66)         Water engine outlet temperature
67)         Water engine inlet temperature
68)         Exhaust gas temperature for each cylinder
69)         Exhaust gas temperature for turbocharger
70)         Water temperature for each cylinder
 

3.6   Misc. Indications

- Engine RPM indicator
- Common engine alarm
- Engine start permission
 

3.7   Controls possible from LCD

- Local / remote mode
- Engine start / stop
- Flasher off
71)         Engine speed raise / low
72)         Emergency stop
 
4.     Battery Charger Panel

4.1   Function

For functioning of devices in Generator Control Panel, LCD etc., 24V/220VDC battery charger of suitable capacity along with Lead acid automotive type rechargeable batteries (2 x 12 V DC) is used. Charger is fully automatic, with trickle and boost charging facility.
 

4.2    Major Components

73)         Transformer
74)         Electronic controllers
75)         AC/DC ammeter, voltmeter
 

4.3    Metering Devices

76)         Voltmeter (with selector switch) for AC input voltage
77)         Voltmeter for DC output voltage
78)         Ammeter for load and battery current
 

4.4    Indications

79)         Mains supply ON
80)         Float mode / Boost mode
81)    Charger Tripped
 
 
 
 

4.5    Controls possible from Charger

82)    Mains supply ON / OFF
83)    Initial / Normal charging mode selection
84)    Fault reset
 

4.6    Protections provided for Charger

85)    Over load / short circuit / earth fault
86)    Over voltage
87)    Battery reverse
 
5.     Vacuum Circuit Breaker (for HT generator)

 

5.1    Function

Vacuum circuit breaker is used to deliver the generated output power to the consumer. It is used for 11KV level of generated voltage.
 

5.2    Major Components

1)              VCB
2)              Metering / Protection CT and PT
3)              Meters, indicators
 
 
 
 
 

5.3    Metering devices

4)              Ammeter with selector switch
5)              Voltmeter with selector switch
 

5.4    Indications

6)              VCB ON
7)              VCB OFF
8)              Auto trip
9)              Spring charged
 
5.5    Current Transformers (with 5 amp. secondary)
10)         Two core Metering / Protection CT (3 nos.) class 1 / 5P10, 20 / 20VA
 
5.6    Potential Transformers (with 110V AC secondary)
11)         Two core potential transformer for Metering/Protection, class 1/3P, 100 /100 VA
 
 
6   INSPECTION AND TESTING
    
6.1 Engine testing :
    
The engine will be run-in at the test bench at worshop before delivery. Subsequent test of 3.5 hours will then be carried out as per following schedule.
 
.   1/2 Hour at 50  % COP
.   1/2 Hour at 75  % COP
.   2   Hours at   100 % COP
.   1/2 Hour at 110 % COP
 
For these tests, engine will be coupled to a hydraulic dynamometer and run on DO as fuel. 
 
6.2 Alternator testing:
Following Routine tests, as per Annexure will be conducted on the alternator at Workshop.
6.2.1    For generator armature, generator field, exciter armature and exciter field.
.   Measurement of resistance.
.   Measurement of insulation resistance.
.   High voltage test.
 
6.2.2 Phase sequence test and voltage balance check.
 
6.2.3 Open circuit characteristics
With generator line voltage recorded against exciter field current.
6.2.4     Short circuit characteristics
With generator line current recorded against exciter field current.
6.2.5     Voltage regulation test
Conducted with AVR in the circuit with reactive loads up to 800 KVA.
 
6.2.6 Control panel test
 
Standard routine tests as per the relevant ISO standard.
 
6.2.7 DG set test.
 
After D.G.Set installation, online checking of all the auxiliary functioning  & fine tuning of fluid   circuit pressure/temperature setting is carried out on load.  This exercise requires one week (Approx.) for completion.  During this time, load for D.G.Set shall be made available by customer as  & when required. After completion of above D.G.Set shall undergo the load tests at site, for 4 hours. For this purpose the load is to be made available by the purchaser. During the tests, all the important parameters, as per our standard procedure will be   checked   & recorded.
 
7   DOCUMENTATION
 
The Scope of Supply includes supply of Technical documentation for the supplied equipment.
 
-   Operating instructions for engine, alternator (1   set).
-   Maintenance manual for engine (1 set).
-   Spare parts catalog for engine.
-    Documentation for auxiliaries and electrical system.
-    Test reports/certificates for engine, alternator & control panel
 

8    PURCHASER'S RESPONSIBILITY
 
8.1 UTILITIES
 
8.1.1 Fuel
 
The fuel of desired specifications shall be provided by the PURCHASER. 
 
In case steam is to be used for fuel heating, a boiler for generating steam to heat HFO in bulk storage tank, settling tank and daily service tank and the fuel piping will have to be arranged.  The capacity of the boiler will depend on the storage capacity of bulk storage tank and piping lengths.
 
8.1.2 Lubricating Oil:
 
Lube oil selected from the approved list of lube oils is to be made available by the purchaser in the lube oil tank.
 
8.1.3 Water
 
The PURCHASER should make available water.
 
 
8.1.4 Air
 
It will be purchaser's responsibility to ensure that the temperature near the engine does not exceed 5 deg C above the ambient.  Necessary data of heat radiations shall be provided on request.
 
A ventilation system can be provided for the powerhouse
 
Quality of air required inside powerhouse is as follows
Dust content<0.5 mg/Nm3 of which
90% Particles are < 5 microns size
99% Particles are < 10 microns size
100% Particles are < 20 microns size
 
8.1.6 Electricity
 
All the auxiliaries for the D.G.Set are suitable for running   on 400VAC/3PH/50HZ supply.  Power for   these auxiliaries is to be supplied by the purchaser.
 
8.2 CONSUMABLES
 
Fuel, Lube oil, cooling water, grease, Jacket water chemicals etc. required   for   normal operation.
 
8.3 CIVIL WORKS:
 
The civil works of the power station is NOT in Supplier scope. We will provide the following drawings and technical information, which will assist your civil consultant in designing the foundation and powerhouse.
 
-   General assembly drawing
-   Powerhouse layout
-   Foundation plan.
-   Schematic piping diagram.
 
Please provide the following data for our information and use:
 
.   Soil bearing capacity
.   Dynamic characteristics of soil
 
 
 
8.4 FOUNDATION:
 
Detail design of the foundation should be made based on the soil bearing capacity at the site by the Purchaser.
 
8.5 APPROVALS:
    
We will provide the purchase with a certificate for compliance with relevant ISO standard from SGS third party.
 
 

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Gold Member Since 2017

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Rating: 5.0/5
Manufacturer/Factory, Trading Company, Group Corporation
Registered Capital
500 RMB
Plant Area
1001~2000 square meters