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
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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 in2.1.1 . 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).
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
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
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) 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
8PURCHASER'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.
Audited Supplier 
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