Ningbo Hyuan Power Industry Co., Ltd.  

Product Name: 1MW/2MW. 3MW/5MW 50Hz/60Hz Diesel/Hfo Generator Set Model NO.: GF Excitation Mode: AC Rotating Exciter Landuse Type of Unit: Low Noise Automation Type Usage: Common Units, Standby Unit, Emergency Crew Conditions of Use: Land Use Speed: Low Speed Output Type: AC Three Phase Cooling Method: Water Cooling Stroke: Six Stroke Installation Method: Fixed Type: Self-Starting Diesel Generator Trademark: HEMG Transport Package: Wooden Specification: 400V/6KV/11KV Origin: China Product Description Technical specification of2.25 MW Diesel Generator Set for power plant from HEMG China2.1 CLIMATIC CONDITIONS2.1.1 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. C2.1.2 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.set2.2.1 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 ENGINE3.1 TECHNICAL DATATechnical 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 rating3.2.1 Rated power under ISO Conditions mentioned in 2.1.1. Maximum continuous rating (MCR) 3400 HP at engine crankshaft. Corresponding rotational speed 600 RPM3.2.2 Under the following limiting ambient conditions :. Air temp. at turbocharger inlet 45 deg. C. Water temp. at charge air cooler inlet32 deg. CDeration 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 OIL3.3.1 FuelEach of the engine offered should be suitable for operation on Diesel or Fuel withmax 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 consumptionThe 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 circuit3.4.1.1 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 engine3.4.1.2 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 CircuitThe 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 system3.4.5.1 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:3.4.7.1Equipment fitted on the engine:- onetype hydraulic governor.- One servo booster with piping for governor- Exhaust gas pyrometric system with thermocouplefor 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.3.4.8.1Equipment 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 includes1) Alternator 2) Control Panel for Generator3) Operation Panel for Generator4) Local control desk5) Air Circuit Breaker panel6) Battery Charger and Batteries (24V/220VDC)7) Control panel for gen-set auxiliaries1. 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 StarNOTEAlternator design considers harmonics in load.2. Control Panel For Generator & Operation Panel For Generator2.1 FunctionControl 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 Components1) Programmable Logic Controller (PLC)2) Generator Protection relays3) Automatic Voltage Regulator4) Meters, indicators, hour counters 5) Push buttons, selector switches6) Engine Frequency Monitoring Unit2.3 Metering Devices7) Analog Engine RPM meter8) Ammeters (3 nos.)9) Voltmeter with selector switch10) Frequency meter11) PF meter12) Analog Excitation fundamental ammeter 13) Analog Excitation harmonics ammeter 14) Counter for running hours2.4 Generator Protections15) Voltage controlled over current16) Under / Over voltage17) Under / Over frequency18) Earth fault19) Very high Alternator bearing temperature20) Reverse power 21) Field failure 22) Master trip 2.5 Status Indications23) Low lube oil priming pressure24) Breaker engaged25) Engine start permission26) Unit ready for excitation27) PLC failure28) Ready for excitation29) DG breaker ON30) DG breaker OFF31) DG breaker Tripped2.6 Alarm Indications32) Low lube oil pressure33) Low water pressure34) Low fuel pressure (in booster control box)35) Low start air pressure36) High lube oil temperature37) High water temperature engine inlet38) High fuel temperature engine inlet (in booster control box)39) Alternator bearing temperature high2.7 Trip Indications40) Very low lube oil pressure41) Very high lube oil temperature42) Very high water engine outlet temperature43) Engine over speed44) Emergency stop45) Speed sensing failure46) Alternator fault47) Under / over voltage48) Under / over frequency49) Voltage controlled over current50) Earth fault2.8 Controls possible - Engine speed raise/low - Engine start - Engine normal and emergency stop 51) Excitation ON / OFF52) Excitation Raise / Low53) Excitation adjust54) Breaker control- Fault indication- Lamp test- Reset3. Local Control Desk3.1 FunctionLocal 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 Component55) Pressure gauges, switches56) Temperature indicators or scanner57) Scanner for Engine exhaust temperatures58) Push buttons, indicating lamps, selector switches59) Flasher 3.3 Pressure Gauges 60) Lube oil filter inlet pressure61) Lube oil filter outlet pressure62) Lube oil cylinder head inlet pressure- Fuel engine inlet pressure- Starting air pressure- Water engine inlet pressure3.4 Pressure Switches63) Lube oil engine inlet pressure3.5 Temperature Indicators / scanner 64) Lube oil engine inlet temperature65) Lube oil engine outlet temperature66) Water engine outlet temperature67) Water engine inlet temperature68) Exhaust gas temperature for each cylinder69) Exhaust gas temperature for turbocharger70) Water temperature for each cylinder3.6 Misc. Indications- Engine RPM indicator- Common engine alarm- Engine start permission3.7 Controls possible from LCD- Local / remote mode- Engine start / stop- Flasher off71) Engine speed raise / low72) Emergency stop4. Battery Charger Panel4.1 FunctionFor 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 Components73) Transformer74) Electronic controllers75) AC/DC ammeter, voltmeter4.3 Metering Devices76) Voltmeter (with selector switch) for AC input voltage77) Voltmeter for DC output voltage78) Ammeter for load and battery current4.4 Indications79) Mains supply ON80) Float mode / Boost mode 81) Charger Tripped 4.5 Controls possible from Charger82) Mains supply ON / OFF83) Initial / Normal charging mode selection84) Fault reset4.6 Protections provided for Charger85) Over load / short circuit / earth fault86) Over voltage87) Battery reverse5. Vacuum Circuit Breaker (for HT generator) 5.1 FunctionVacuum 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 Components1) VCB2) Metering / Protection CT and PT3) Meters, indicators5.3 Metering devices4) Ammeter with selector switch5) Voltmeter with selector switch5.4 Indications6) VCB ON7) VCB OFF8) Auto trip9) Spring charged5.5 Current Transformers (with 5 amp. secondary)10) Two core Metering / Protection CT (3 nos.) class 1 / 5P10, 20 / 20VA5.6 Potential Transformers (with 110V AC secondary)11) Two core potential transformer for Metering/Protection, class 1/3P, 100 /100 VA6 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 % COPFor 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 characteristicsWith generator line voltage recorded against exciter field current.6.2.4 Short circuit characteristicsWith generator line current recorded against exciter field current.6.2.5 Voltage regulation testConducted with AVR in the circuit with reactive loads up to 800 KVA.6.2.6 Control panel testStandard 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 documentATIonThe 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 RESPONSIBILITY8.1 UTILITIES8.1.1 FuelThe 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 WaterThe PURCHASER should make available water.8.1.4 AirIt 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 powerhouseQuality of air required inside powerhouse is as followsDust content<0.5 mg/Nm3 of which90% Particles are < 5 microns size99% Particles are < 10 microns size100% Particles are < 20 microns size8.1.6 ElectricityAll 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 CONSUMABLESFuel, 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 soil8.4 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.