Documente Academic
Documente Profesional
Documente Cultură
FOR
3 SETS VASA 18V32
Page 2 (38)
TABLE OF CONTENTS
A.0 EXECUTIVE SUMMARY ...................................................................................................... 3
A.0.1 TYPE OF THE PLANT ............................................................................................... 3
A.0.2 PLANT MAIN DATA AND CONDITIONS ............................................................... 4
A.0.3 SPECIAL FEATURES ................................................................................................. 5
A.0.4 CODES AND STANDARDS....................................................................................... 5
A.1 GENERATING SET................................................................................................................. 6
A.1.1 DIESEL ENGINE......................................................................................................... 6
A.1.2 GENERATOR............................................................................................................. 15
A.1.3 COMMON BASE FRAME ........................................................................................ 17
A.1.4 ELASTIC MOUNTING ............................................................................................. 17
A.1.5 COUPLING ................................................................................................................ 17
A.1.6 FLEXIBLE CONNECTIONS .................................................................................... 17
A.2 MECHANICAL AUXILIARY SYSTEM............................................................................. 18
A.2.1 FUEL SYSTEM ......................................................................................................... 18
A.2.2 LUBRICATING OIL SYSTEM ................................................................................. 20
A.2.3 COMPRESSED AIR SYSTEM ................................................................................. 21
A.2.4 COOLING SYSTEM ................................................................................................. 22
A.2.5 CHARGE AIR SYSTEM ........................................................................................... 24
A.2.6 EXHAUST GAS SYSTEM........................................................................................ 24
A.3 ELECTRICAL SYSTEM....................................................................................................... 25
A.3.1 MAIN SWITCHGEAR .............................................................................................. 25
A.3.2 STATION SERVICE SYSTEM.................................................................................. 27
A.3.3 DC SYSTEM.............................................................................................................. 28
A.4 AUTOMATION, MONITORING AND SUPERVISION................................................... 29
A.4.1 CONTROL AND AUTOMATION SYSTEM ........................................................... 29
A.5 HEAT RECOVERY SYSTEM . . 3 4
A5.1 STEAM GENERATION .. . .34
A.6 EMISSION CONTROL SYSTEM 3 7
A6.1 SELECTIVE CATALYTIC REDUCTION (De-NOx) SYSTEM . 3 7
A.7 TOOLS..................................................................................................................................... 38
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A.0
EXECUTIVE SUMMARY
Design and construction
The essence of the design is simplicity and reliability Repairs and normal maintenance may
be performed by means of conventional tools completed with special tools included in this
scope of supply.
The equipment is designed to prevent accidental contract with live or tensional parts and to
minimize ingress of dust and dirt.
Quality control, test and inspection procedures and designed to ensure product quality with
special attention paid to tests of the diesel engine and inspection of the final installation.
Main parts with devices like valves, pumps etc. are marked with engraved name plates
indicating its item code.
English is used in all documents, correspondence and name plates.
A.0.1
Page 4 (38)
A.0.2
Plant Ratings
Voltage
Frequency
Auxiliary voltage
18900 kWe
23625 kVA, power factor 0.8
6.9
60
440
110
kV
Hz
V AC, 3phase, 4 wire
V DC
Ambient Conditions
The equipment will be designed and constructed for operation at the extreme site
conditions of:
Ambient temperature, max.
Ambient temperature, min.
Engine room air temperature, max.
Engine room air temperature, min.
Altitude, max.
Water temperature to charge
air cooler, max.
Wet bulb temperature, max.
39
10
10
0
100
C
C
o
C above ambient temperature
o
C
m a.s.l.
o
38 oC
28 oC
At extreme site temperature mentioned above, the plant gross electrical production will be:
18900 kWe. The DG-set output is calculated according to the ISO 3046-1986(E) derating
standards.
Tolerances according to ISO 3046-1986(E).
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A.0.3
SPECIAL FEATURES
Vibration And Noise Control
Transmission of vibration and structure borne noise is minimized by having the DG set
flexibly mounted on to the foundation, to the building as well as pipes and steel structures.
Torsional vibration in the engine-generator shaft system is minimized by means of a
flexible coupling between the engine and generator.
Start Up And Loading
Fast start up and loading of generating set is possible, provided that the engine is preheated
and prelubricated.
Operation And Maintenance Support
The Operation and Maintenance Manuals are tailor made for each project and covers the
whole plant, thus enabling the correct operation and maintenance of the plant throughout
its life time.
The World wide Service organization and the Customer Support Team will assist the
customer to organize the plant day-to-day operation and to set-up optimum reporting
follow-up, incentives, etc. schemes, thus laying the foundation for long term successful
operation of the plant.
A.0.4
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A.1
GENERATING SET
A.1.1
DIESEL ENGINE
3 Diesel engines Wartsila Vasa 18V32
The engine is four stroke, direct injected, turbocharged and intercooled design.
Configuration
Number of cylinders
Cylinder bore
Stroke
Speed
Mean piston speed
Compression ration
Mean effective pressure
Swept volume per cylinder
Number of valves
Direction of rotation faced towards flywheel
Engine shaft output
Vee form
18
320
350
720
8.4
13.8:1
21.3
28.15
2
2
Clockwise
6660
mm
mm
rpm
m/s
bar
dm3
inlet valves
outlet valves
kWm
Engine shaft output corresponds to 100% load of the engine at ISO 3046/I-1986(E)
conditions. The fuel rack position is blocked at 100% load.
The diesel engine is designed for continuous heavy fuel duty and can be started and
stopped on heavy fuel oil provided that the fuel is heated to operating temperature.
Fuel consumption according to ISO 3046 standards and tolerance of 5% without engine
driven pumps and with fuel net calorific value of 42,700 kJ/kg:
100% load
85% load
187 g/kWh
185 g/kWh
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Control System
The engine is provided with the following control and protection equipment.
-
Thermometers
Thermometers with protecting wells are fitted on the engine for reading following
temperatures:
- Fuel oil before the engine
- HT-water before engine
- HT-water after turbocharger
- HT-water after engine
- LT-water before the charge air cooler
- LT-water after charge air cooler
- Charge air in the air receiver
- Exhaust gas after each cylinder
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Starting air
210 m3/h
210 m3/h
123 m3/h
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Page 13 (38)
LUBRICATING OIL
Only lubricants that are approved by Wartsila Diesel Oy are allowed to be used. The
properties of used lubricating oil must stay within limits given below. More detailed
information is available in the engine manuals.
Viscosity, SAE 30, max.
max.
SAE 40, max.
Max.
Flash point, open cup, min.
min
Water, max.
BN
Insolubles, max.
140 cSt
15 cSt
212 cSt
19 cSt
-50
170
0.5
15-40
2
at 40oC
at 100 oC
at 40 oC
at 100 oC
o
C from nominal value
o
C
%
*)
%
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Limits for engine cooling (primary circuit), turbine washing, and separator operating water:
pH at 25oC
Conductivity at 25 oC (mS/m)
Total hardness Ca 2+ + mg2+ (odH)
Silica as SiO2, (mg/l)
Chlorides Cl -, (mg/l)
Sulphates as SO 42-, (mg/l)
>7
<10000
2-10
<50
<60
<150
General appearance
For cooling tower and heat exchangers (secondary circuit), values are like above, but
Chlorides Cl - should be 150-300 mg/l. If chlorides are above 300 mg/l titan heat
exchangers to be used.
CHARGE AIR
-
Cement dust
10.0 mg/Nm3
Calcium hydroxide
5.0 mg/Nm3
Chlorine
1.5 mg/ Nm3
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A.1.2
GENERATOR
3 Self-cooled 3-phase brushless, salient pole type, synchronous generator(s)
Nominal output
Power factor
Voltage
Current, In
Frequency
Speed
Runaway speed
Efficiency at rated output, voltage and p.f. 0.8:
Continuous short circuit current
Insulation class / temperature rise
Enclosure
Standard
7875 kVa
0.8
6900 V, adjustment range 5%
658 A
60 Hz
720 Rpm
864 Rpm
96.4 %
About 3 x In
F/F
IP21
IEC34
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A.1.3
A.1.4
ELASTIC MOUNTING
3 Sets of steel spring eleme nts for flexible mounting of the DG-set onto the foundation
block
A.1.5
COUPLING
3 Flexible coupling(s) between engine and generator shaft
3 Flywheel cover(s) for the flywheel and the flexible coupling
A.1.6
FLEXIBLE CONNECTIONS
3 Set(s) of flexible hoses and bellows for connection of the engine to external piping
systems
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A.2
A.2.1
FUEL SYSTEM
The main function of fuel oil system is to provide the engine with fuel oil of correct flow,
pressure, viscosity and degree of purity. The power plant is designed for using Heavy
Fuel Oil as the main fuel. Light Fuel Oil is used as a back-up fuel.
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A.2.2
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A.2.3
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A.2.4
COOLING SYSTEM
Cooling as well as lubricating system is vital part to enable reliable and continuous power
plant operation. Cooling system consists of primary circuit (engine cooling system, water
flow through the engine) and secondary circuit where water is not directly connected to the
engine, but via heat exchangers. In case of radiator cooling, there is not need to have two
separate systems, but only primary cooling circuit exists.
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288 m3/h
2.5 bar
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A.2.5
A.2.6
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A.3
ELECTRICAL SYSTEM
A.3.1
MAIN SWITCHGEAR
Main switchgear contains air insulated, metal enclosed and withdrawable circuit breakers.
Single busbar is provided with IP3x exterior and IP2x interior enclosure, fulfilling relevant
IEC 298 and IEC 694 standards.
Generated electrical power is transferred to the consumers via main switchgear.
Switchgear is dimensioned to withstand electrical power characters as stated below.
Rated voltage
7.2 kV
Rated current for busbars
2000 kA
Rated short circuit strength Ith/1s
25 kA
The main switchgear circuit breakers are equipped with auxiliary contacts, charging motors,
closing and shunt tripping coils. Current and voltage transformers have a rated burden to
suit with connected measuring and protection devices. Accuracy class for protection
transformers is 10P10 and for measuring transformers cl. 0.5.
THE MAIN SWITCHGEAR CONTAINS THE FOLLOWING EQUIPMENT
3 Generator cubicle(s), rated current 1200 A
Apparatus of main circuit:
1 SF6 or vacuum circuit-breaker
3 Current transformers
2 Voltage transformers
1 Earthing switch
1 Cable transformer for earth fault
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A.3.2
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A.3.3
DC SYSTEM
The DC-system is a system of its own in the power plant. It feeds DC-power to the
control panels in the control room (panels including start/stop automation, synchronization,
generator protection and the alarm annunciation of the power plant).
The power plant is equipped with DC-system to ensure a safe operation and the power
plant is not dependent of the AC auxiliary voltage to ensure a safe shut-down in case of
failure in the auxiliary voltage supply.
Combined DC supply unit consists of Battery, Battery Charger, DC distribution and DC
supervision.
1 Battery
Type
Size
Voltage (DC)
Lead Acid
75 Ah/10h
110 V
2 Charger(s)
Charging current
12 A
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A.4
A.4.1
Page 30 (38)
The mimic contains the power station bus and position indicators for generator breakers
and synchronisable breakers with synchronizing order push buttons.
The common section is typically located at the left end of the central control panel facing
the front.
Central control panel enginewise section
Each engine has one enginewise section in the central control panel. This section
contains essential meters, control and operation switches and protection relays for the
DG-set.
The meters include three ammeters, one voltage meter with a selector switch for selecting
any of the three line-to-line voltages, an active power meter with energy metering, a
reactive power meter, a power factor meter, a frequency meter, a speedometer with a
selector switch for selecting the engine speed or turbocharger speed for display and a
running hour meter.
The control switches include a master switch for selecting manual or automatic operating
mode and manual operation switches (engine and generator control mode switches,
increase/decrease controls and synchronizing selection). It also contains push buttons for
starting and stopping, breaker open and close control as well as breaker trip and engine
shutdown reset.
The protection relays include functions for reverse power, overvoltage, overcurrent and
ground fault protection. Generator differential overcurrent and loss of excitation
protections complete the protection scheme (As standard only when S>5MVA).
Local control panels
The local control panels are used for controlling the auxiliary systems and are factory
installed to the respective units. They include control switches, push buttons and
indicator lights for the local supervision and control of the auxiliary systems. They give
more detail information about the specific part of the plant and allow the control of the
auxiliary unit.
Operators station
The operators station is used for monitoring the power plant. It reads information from
process stations with a bus operating at control network level and visualizes the
information in easy-to-read displays on the PC monitor. The operators station also
includes the alarm listing and printing, reporting and trending. The extended automation
system includes one operators station with facilities for further expand.
The operators station is based on a PC based SCADA software running in Microsoft
Windows NT or 3.11 Windows for Workgroups. The operator station includes a large
monitor, one matrix type printer for alarm printing, one black & white printer for reporting
and one colour printer for trend display screen prints. The electricity to operators station
hardware is supplied from an uninterruptible power supply.
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Information from the process stations is arranged into groups which are displayed as pages
on the monitor. Enginewise displays include individual pages for the engine fuel system,
the engine lubrication oil system, the engine starting air system, the engine cooling system,
bearing and exhaust gas temperatures and a DG set overview display. The power plant
common system displays are formed based on project related equipment, however typically
the displays include the power plant fuel system, starting air system and an electrical single
line diagram.
The operators station stores data from all analogue monitoring points to hard disk. This
information can be called up in the historical trends displays. The trend displays are
scaled to show information from one minute up to one week back.
The operators station reporting system includes the following reports; Plant and engine
daily to operation data (optionally shift report), consumption and production reports (day,
month, year and multi-year reports, optionally week and shift reports), duration curve for
engine load and fault code registration.
Process stations
The automation system includes one process station for each engine, which is referred as
the enginewise process station. This process station monitors the engine with the engine
instrumentation and performs alarm and shutdown functions which are needed for safe
operation of the engine. It also performs the engine automatic operation sequences such
as the starting and the stopping sequences as well as contains the automatic load limiter
based on ISO guidelines. The enginewise process station is typically located in the
engine local panel and it is connected to the operators station at control network level in
order to provide the operators an easy method for monitoring the engine operation. The
enginewise process station is designed to operate independently of other process stations in
order to maximize the reliability.
The automation system also includes one process station for monitoring the power plant
common functions such as the fuel system or the starting air system. This station is
referred as the power plant common process station. It is normally located in the central
control panel/common section and it is connected to the operators station at the control
network level.
Engine instrumentation
The engine instrumentation is connected to the local control panels and monitored in the
control room by operator station. The engine instrumentation includes analogue
temperature and pressure sensors and switches for alarm information and stop orders.
Alarms, stop orders and measurements (indicating the actual value) are described in list
below.
Shutdowns:
- low lubricating oil pressure (digital)
- high HT-water temperature after engine (digital)
- high exhaust gas temperature after cylinder (analogue)
- high charge air temperature (digital)
- overspeed (digital)
- high main bearing temperature (analogue)
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Alarm signals:
- low fuel oil pressure (analogue)
- fuel leakage inside hot box (digital)
- low fuel oil inlet temperature (analogue)
- low lubricating oil pressure before engine (analogue)
- high lubricating oil inlet temperature (analogue)
- high differential pressure across lubricating oil filter (analogue)
- low lubricating oil level in oil sump (digital)
- low starting air pressure (analogue)
- high HT-water temperature after engine (analogue)
- low HT-water pressure (analogue)
- low LT-water temperature (analogue)
- high LT-water temperature before engine (analogue)
- high exhaust gas temperature after cylinder (analogue)
- high exhaust gas temperature after turbocharger (analogue)
- overspeed (digital)
- high main bearing temperature (analogue)
- turning gear engaged (digital)
Measuring:
- fuel oil pressure
- fuel oil inlet temperature
- lubricating oil pressure before engine
- lubricating oil inlet temperature
- lubricating oil temperature after engine
- pressure across lubricating oil filter
- starting air pressure
- HT-water temperature before engine
- HT-water temperature after engine
- HT-water pressure
- LT-water temperature before engine
- LT-water temperature after engine
- charge air pressure after compressor
- exhaust gas temperature after each cylinder
- exhaust gas temperature after turbocharger
- main bearing temperature
The instrumentation also contains local meters to indicate temperature and pressure values
locally.
Local meters:
- fuel oil pressure
- fuel oil temperature
- lubrication oil pressure before engine
- lubricating oil temperature before engine
- starting air pressure
- HT-water pressure
- LT-water pressure
- HT-water temperature before engine
- HT-water temperature after engine
- HT-water temperature after turbocharger
- LT-water temperature before charge air cooler
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Field instrumentation
The field instrumentation includes switches, analogue sensors and local meters. The
important status information and analogue measuring results are transferred to the control
room and monitored by the operators station. The tank level alarms, common alarms for
HFO separator unit and booster unit, high differential pressures in lube oil and safety filter
and return fuel oil pump start/stop indications are presented in the operators station.
More detail status information is shown in the local control panels. Analogue information
is available about the tank levels and the fuel viscosity.
The field instrumentation includes also local meters to show pressure, temperature and
level values locally beside the measuring point. Description of them is presented in
context of each unit or equipment.
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A.5
A.5.1
STEAM GENERATION
The exhaust gas boilers are of water tube with forced circulation through the evaporator
unit. The water circulation is maintained by circulation pumps. The steam is separated
from the water in the steam drum. The drum is common for several boilers. A non-return
valve on the steam outlet from the drum prevents back flow when the boiler is not in use.
The water level in the steam drum is controlled by a modulating control valve regulating
the water flow coming from the feed water pump.
When operating on HFO, additional steam generation is needed to provide steam in cases
when the engine(s) are not running and thus the exhaust gas boilers do not generate steam.
3 Exhaust gas boiler(s)
Water flows inside the tubes and the exhaust gas flow in the common boiler space.
Boiler equipment:
- Evaporator unit
- Inlet and outlet hoods with inspection covers
- By-pass damper
- Soot blowing equipment (manual)
- Standard assortment of valves
- Blow down drain
- Safety valves, relief valves, and fitting
- Insulation and cladding
- Counter flanges, bolts, nuts, and gaskets
- Mounting pads or supports
Capacity at boiler outlet: (sit conditions as specified in A. 0.2, 100% engine load)
Steam generation
2.8 t/h at 184.1C
Steam pressure (saturated)
11 bar(a)
Recovered heat with a feed
water temp. of 90C
1981 kW
Page 35 (38)
1 Steam drum
The steam drum is equipped with built-in water/steam separation. The water level in the
drum is controlled by a level controller connected to a control valve in the feed water pipe.
The water is circulated from the steam drum through the evaporator section and back to
the steam drum by means of a centrifugal pump.
The steam drum includes:
- Non-return valve
- Blow down outlet
- Safety valves and control valve
- Insulation
- Standard instrumentation
Capacity of the steam drum
Working pressure
Steam flow
11 bar(s)
8.4 kg/h
Page 36 (38)
pH at 25C
Conductivity at 25C
Total hardness Ca+ +Mg+
Oxygen as O2
Carbon dioxide as fixed CO2
Total iron Fe ++ Fe +
Copper as Cu
Silica as SiO2
Organic matter, KMnO4 cons
Oil
Chlorides Cl
Phosphates as PO 4Sulphates as SO4Sodium as Na +
General appearance
A
>7
C
8.5-9.5
<1000
<10
<0.1
<0.01
<25
<0.05
<0.01
<80*
<10
<1
150-300** <5
D
E
10.5-12 8.5-9.5
<1000
<0.5
<0.05
mS/m
dH
2-10
mg/l
mg/l
mg/l
mg/l
mg/l
<60*
mg/l
<300
mg/l
mg/l
<80
<300
mg/l
10-20
mg/l
<150
mg/l
clear, colourless, free of undissolved materials
<0.05
<0.01
15-30
Note: valves are valid only for saturated stem systems with working pressure below 22 bar(a)
Page 37 (38)
A.6
A.6.1
SCR-catalyst reactors
-
Injection nozzle
Injection piping
Valves, flanges
Control panels
The system measures NO and calculates the total NOx emissions in ppm at reference
oxygen content.
Page 38 (38)
A.7
TOOLS
1 Set of maintenance tools for engine
1 Set of maintenance tools for special operations
1 Set of general tools
1 Set of maintenance tools for turbocharger