diesel engine report

ME 521 – POWER PLANT DESIGN

2014

1

Aljon M. Altiche

Efrel John L. Manlapaz

Romyrick L. Gliponeo

Emannoel M. Brimon

In a diesel power station, diesel engine is used as the

prime mover. The diesel burns inside the engine and

the products of this combustion act as the working

fluid to produce mechanical energy. The diesel engine

drives alternator which converts mechanical energy

into electrical energy.

2

Diesel power plants is in the range of 2 to 50 MW capacity. They

are used as central station for small or medium power supplies.

They can be used as stand-by plants to hydro-electric power

plants and steam power plants for emergency services.

They can be used as peak load plants in combinations with

thermal or hydro-plants.

They are quite suitable for mobile power generation and are

widely used in transportation systems such as automobiles,

railways, air planes and ships.

Now-a-days power cut has become a regular feature for

industries. The only solution to tide over this difficulty is to install

diesel generating sets.

3

Diesel Engine

Air intake system

Exhaust system

Fuel supply system

Cooling system

Lubricating system

Starting system

4

A diesel engine (also known as a compression-

ignition engine) is an internal combustion

engine that uses the heat of compression to initiate

ignition and burn the fuel that has been injected into

the combustion chamber. This contrasts with spark-

ignition engines such as a petrol engine(gasoline

engine) or gas engine (using a gaseous fuel as

opposed to gasoline), which use a spark plug to ignite

an air-fuel mixture.

8

This occurs in two steps. First, the fuel reacts

chemically (burns by self ignition) and releases energy

in the form of heat. Second the heat causes the

gasses trapped in the cylinder to expand, and the

expanding gases, being confined by the cylinder, must

move the piston to expand. The reciprocating motion

of the piston is then converted into rotational motion

by the crankshaft.

9

1. Suction stroke, with inlet valve open, fills cylinder with air.

2. Compression stroke raises pressure to about 35kg/cm2.

Fuel injection starts at or near end of compression stroke.

3. High air temperature caused by compression ignites fuel.

Burning mixture expands, pushing piston down on working stroke.

4. Exhaust valve open: rising piston clears cylinder.

11

The ideal thermal cycle of the Diesel engine begins with

the working medium at state 1, it is first polytropically

compressed to state 2, then heat is added during a limited

isobaric expansion, after which a polytropic expansion to

the initial volume reduces pressure to state 4. The ideal

work produced by the cycle is represented by its area, and

the mean effective pressure is its average height.

12

13

a

b c

d

4 Stroke Diesel Engine

is an internal combustion engine in which the piston completes

four separate strokes which comprise a single thermodynamic cycle

2 Stroke Diesel EngineLike the four-stroke engine, the two-stroke engine must go

through the same four events: intake, compression, power, and

exhaust. But a two-stroke engine requires only two strokes of the

piston to complete one full cycle(crankshaft).

14

INTAKE

EXHAUST

Two stroke diesel engine:

A system with air filters, ducts and supercharger that

supplies necessary air to the engine for fuel

combustion. It consists of pipes for the supply of fresh

air to the engine manifold. Filters are provided to

remove dust particles from air which may act as

abrasive in the engine cylinder.

It also improves the turbocharged or supercharged

engine’s efficiency, and it cools the compressed air

after being compressed.

16

Dry Filter – A type of system where paper, cloth, or a

metal screen material is used to catch and trap dirt

before it enters the engine.

Wet Filter – In this system the air is sucked or

bubbled through a housing that holds a bath of oil

such that the dirt in the air is removed by the oil in the

filter. The air then flows through a screen-type material

to ensure any entrained oil is removed from the air.

17

18Wet Filter Air Intake System

To E

ng

ine

20

A system that leads the engine exhaust gas outside

the building and discharges it into atmosphere. A

silencer is usually incorporated in the system to

reduce the noise level. It is mainly composed of

manifold, cylinders, muffler and exhaust pipe.

21

Silencer

Expansion Joint

Exhaust manifoldCylinders

First, the exhaust system routes the spent combustion

gasses away from the engine, where they are diluted

by the atmosphere. This keeps the area around the

engine habitable.

Second, the exhaust system confines and routes the

gases to the turbocharger, if used.

Third, the exhaust system allows mufflers to be used

to reduce the engine noise.

22

a. The noise should be reduced to a tolerable degree.

b. It should be exhausted well above the ground level

to reduce the air pollution at breathing level.

c. The pressure loss in the system should be reduced

to minimum.

d. The vibrations of exhaust system must be isolated

from the plant by use of flexible exhaust pipe.

e. A provision should be made to extract the heat from

exhaust if the heating is required for fuel oil heating

or building heating or process heating.

23

A system consists of storage tank, strainers, fuel

transfer pump and all day fuel tank.

26

a. The fuel oil is supplied at the plant site by rail or

road. The oil is stored in the storage tank.

b. From the storage tank, oil is pumped to smaller all

day tank at daily or short intervals.

c. From this tank, fuel oil is passed through strainers to

remove suspended impurities.

d. The clean oil is injected into the engine by fuel

injection pump (fuel injection system).

27

28

Day tanks

Simple Suction system

In a simple suction system, the oil is taken by a suction pump

driven by engines from service tank located a few cm below the engine

level. Such pump delivers constant volume of fuel, therefore, an

overflow line is required back to the tank. This system is used for small

capacity plant.

Transfer system

In transfer system, the motor driven pump takes the oil from

main storage and supply to the day storage tank. The oil from day-

storage tank flows under gravity to the engine pump.

29

A system that includes water circulating pumps,

cooling towers or spray ponds and water filtration

plant. Small engines may be served with a cellular

heat exchanger (radiator), through which the air is

drawn by means of fan.

32

If the engines are not properly cooled, the

temperature existing inside engines would disintegrate

the film of lubricating oil on the liners and wrapping of

valves and pistons takes place. The proper cooling of

the engine is absolutely necessary to extend the life of

the plant. Therefore, exit temperature of the cooling

water must be controlled. If it is too low, lubricating oil

will not spread properly and wearing of piston and

cylinder takes place. If it is too high, the lubricating oil

burns. Therefore, the maximum exit temperature of

the water is limited to 70°C.

33

34

The temperature of the burning fuel inside the engine

cylinder is 15000C to 20000C. In order to lower this

temperature water is circulated around the engine.

The hot water leaving the jacket is passed through the

heat exchanger.

The heat from the heat exchanger is carried away by

the raw water circulated through the heat exchanger

and is cooled in the cooling tower

35

to Oil

Cooler

A system that includes the oil pumps, oil tanks, filters,

coolers and connecting pipes. The function of the

lubrication system is to reduce the friction of moving

parts, reduce the wear and tear of the engine parts

and also helps to cool the engine .

38

The role played by the lubrication system in diesel

power plant is more important than any other plant

because of very high pressures and small clearance

in these engines. The life of the engine, the overall

efficiency of the plant and possible continuous service

of the plant are dependent on the effectiveness of the

lubrication system.

39

Piston and cylinders

Crankshaft and connecting rod bearings

Gears or other mechanism designed to transmit

motion to auxiliaries.

Integral injection or scavenging air compressors.

40

Engine Starting by an auxiliary small engine

Compressed air system

Starting by electric motor

43

It is composed of two engine:

1. Diesel engine that is main engine.

2. Small petrol engine.

44

Joining:

• Diesel engine and petrol engine are joined by clutch and gear

arrangements.

• Small petrol engine can be easily started by means of manual

operations

45

Working process:

• First clutch is disengaged and petrol engine is started by hand

operated system.

• Then clutch gradually engaged and the power is transferred to

diesel engine.

• Automatic disengagement of clutch takes place after main engine

has started.

• The capacity of the starting petrol engine is just sufficient to

overcome the friction of the main diesel engine.

The compressed air system is generally used for

starting large diesel engine employed for power plant.

In this system compressed air a pressure of 17 bar is

supplied from an air bottle to the engine cylinder either

through a distributor or directly through inlet manifold.

In case of multicylinder engines, at least one cylinder

remains on the suction stroke.

46

47

Working process:

• When compressed air under the pressure enters cylinder, it

pushes the cylinder thereby causing entire engine crankshaft

assembly to rotate.

• Meanwhile the suction stroke of some other cylinder takes place

and the compressed air again pushes the piston of this cylinder

and causes the engine crank assembly to rotate.

• Gradually the engine gains momentum and by turning on the fuel

supply, engine will start running.

This system consists of an electric motor which is

drives pinion which engages a gear toothed rim on

engine.

A storage battery of 12 to 36 volts is used to supply

power to an electric motor.

The main advantages of electric starting are its

simplicity and effectiveness. This system is used for

small diesel engine.

48

The engine should not be stopped abruptly. In order to

stop engine, the speed should be decreased gradually

until no power is delivered by generator .Then the

engine is disconnected from the bus bars and is

allowed to run idle for some time.

49

Stopping fuel supply

Keeping exhaust valve open

Shutting of air supply

Stopping the action of injection pump.

50

Plant layout is simple. Hence it can be quickly installed

and commissioned, while the erection and starting of a

steam power plant or hydro-plant takes a fairly long time.

Quick starting and easy pick-up of loads are possible in a

very short time.

The load operation is easy and requires minimum labours.

Efficiency at part loads does not fall so much as that of a

steam plant.

Fuel handling is easier and no problem of ash disposal

exists.

The plant is smaller in size than steam power plant for

same capacity.52

Plant capacity is limited to about 50 MW of power.

Diesel fuel is much more expensive than coal.

The maintenance and lubrication costs are high.

Diesel engines are not guaranteed for operation under

continuous, while steam can work under 25% of

overload continuously.

53

55

DMPC – CATAINGAN

SATELLITE PLANT

DMPC – AROROY

SATELLITE PLANT

DMPC – MAIN

PLANT

56

Power Plants Installed and Operated by DMCI Masbate Power Corporation

2 x 6.2MW HFO Gensets

2 x 2.0MW Diesel Gensets 1 x 2.0MW Diesel Gensets

2 x 1.0MW Diesel Gensets



1 x 1.0MW Diesel GensetsMobo Power Plant

Cataingan Satellite Plant

Aroroy Satellite Plant

24.4 MW Total Plant Capacity

57

MAIN PLANT

58

MAIN PLANT

CAPACITY & CONFIGURATION

GENERATOR UNITS Speed (Category) Installed MW CapacityDependable MW

Capacity

NIIGATA 1 600 RPM (Medium Speed) 6.2 5.8

NIIGATA 2 600 RPM (Medium Speed) 6.2 5.8

CATERPILLAR 1 1800 RPM (High Speed) 2.0 1.6


MITSUBISHI 3 1800 RPM (High Speed) 1.0 0.8

59

CATAINGAN SATELLITE PLANT

60

CATAINGAN SATELLITE PLANT



Capacity




61

AROROY SATELLITE PLANT

62

AROROY SATELLITE PLANT



Capacity



63

DIESEL ENGINES

Main Plant,

Mobo

(MW)

Curvada,

Cataingan

(MW)

Bangon,

Aroroy

(MW)

TOTAL

(MW)

NIIGATA 1 6.2 6.2

NIIGATA 2 6.2 6.2

CATERPILLAR 1 2.0 2.0




MITSUBISHI 1 1.0 1.0




TOTAL INSTALLED

CAPACITY (In MW) 17.4 4.0 3.0 24.4

POWER PLANT’S INSTALLED CAPACITY

64

DIESEL ENGINES

Main Plant,

Mobo

(MW)

Curvada,

Cataingan

(MW)

Bangon,

Aroroy

(MW)

TOTAL

(MW)

NIIGATA 1 5.8 5.8

NIIGATA 2 5.8 5.8









DEPENDABLE

CAPACITY (In MW) 16.4 2.4 2.4 21.2

POWER PLANT’S DEPENDABLE CAPACITY

65

Why Satellite Plant Exists?

1. It is the DMPCs alternative solution in the absence of

NPCs 69 KV Transmission Line (A government’s

unfinished project).

2. Due to a long extended 13.8 KV Distribution Line of

MASELCO which resulted in a “Low Voltage” in the far

end of the DT.

What are its Primary Purposes?

1. To correct “Low Voltage” Problem at far end.

2. To minimize “System Loss” of the Off taker.

3. To minimize prolong “Brownouts” at areas affected by

Line Repair Maintenance.

4. To bring more “Reliable Power” to the consumers.

NIIGATA GENSET

67

NIIGATA ENGINE:

Model: 18V32CLX-1

M.C.R. output: 6.2MW

No. of cycles: 18

Cylinder bore: 320MM

Piston stroke: 420MM

Rated speed: 600RPM

Turbocharger: NR34/R

Max speed: 25400RPM

68

CATERPILLAR GENSET

69

MITSUBISHI GENSET

70

AIR INTAKE SYSTEM

AIR INTAKE FILTER

“Auto-mazed Air Filter”

71

LUBE OIL SYSTEM

75

COOLING SYSTEM

COOLING SYSTEM

100KL RAW WATER

STORAGE TANK

76

H2O TREATMENT

77

PRIMARY COOLING SYSTEM

20KL SOFT H2O

STORAGE TANK

78

PRIMARY COOLING SYSTEM

JACKET H2O PUMP – 30KW

79

SECONDARY COOLING SYSTEM

MODEL: LBC 500

NOMINAL H2O FLOW: 6500L/M

AIR VOLUME: 2600M3/M

80


AIRCOOLER

81


LUBE OIL COOLER

RAW WATER IN

82

FUEL SYSTEM

84

FUEL SYSTEM DRAIN

85

SLUDGE SYSTEM

SUMP PIT

SUMP PIT

PUMP

86

EG – 160 (438 KVA)

87

SLUDGE STORAGE AREA

88

The Niigata Alternator

89

MEDIUM VOLTAGE SWITCHGEAR

BUS PT

PANEL

NII-2

PANEL

NII-1

PANEL

20-MVA

X’FORMER

PANEL

1.5-MVA

AUX.

X’FORMER

PANEL

Single Line Diagram

IEC/DMPC Single Line Diagram-distribution line copy.jpg

DMPC Single Line Diagram-distribution line.pdf

90

CONTROL ROOM

ENGINE-1 ENGINE-2

SYNCHRONIZIN

G PANEL

AMC-1 /

AMC-2

ANCILIARY

CONTROL

PANEL

91

Actual Flow of Power Distribution

69-KV TRANSMISSIONLINENPC 69KV POWER SUB-STATION

WITH 10MVATRANSFORMER

13.8KV

DISTRIBUTIONLINE

CONSUMERS

DMCI MASBATE POWER

PLANT

20MVA STEP-UP

POWER SUB-STATION

F1 & F3

F2

F1 – FEEDER 1

F2 – FEEDER 2

F3 – FEEDER 3

STEP-DOWN DIST.

TRANSFORMER

DMPC

DMPC

MASELCO

MASELCO

DMPC

NPC

93

At shaft under ISO conditions = 6600 kW

Number of strokes = 4 (four)

Cylinder Power = 550 kW/cylinder

Number of cylinders = 12

Nominal speed = 600 rpm

Diesel Engine Unit = 3

Capacity Installed = 18.9 MW

Capacity Dependable = 14.9 MW

94

OPERATION PROCEDURES

Pre-Operation Procedures

Verify order of operation with Shift Supervisor On-duty prior to carrying out pre-

startup procedures.

Visually check the Jacket Water [JW] and Injector Cooling [IC] Water

expansion tanks for proper level.

Check inlet and outlet valves of Nozzle and Jacket Waters systems for proper

open or close positions.

Press JW and NC water pumps start button located on the Engine Control

Panel [ECP].

Energize JW and IC water heaters by pressing the “ON” button located on the

Heaters Control Panel [HCP].

Check the level of the various engine tanks and auxiliary equipment.

Cooling Tower Pond

Oil Sump Tank

Cylinder Lubricating Oil Tank

Bunker fuel service and settling tank

Diesel storage tanks

Turbocharger oil level

Governor oil level

Outboard bearing oil level

Air pressure for 30 and 8 bar tanks

95

Verify that fuel control linkages and injection pump plunges moves freely.

Manually lubricate cylinder liners by turning the hand crank of the cylinder

lubricators and check that excessive force is not needed to turn the cranks.

Check that the various valves for the engine cooling, lubrication, fuel system and

air system are in the correct position.

Verify with Auxiliary Operator/Maintenance that the lube oil separator/centrifuge

of engine in schedule has been running normally. (The separator must be put in

operation at least four hour before engine operation to remove accumulated dirt

or settled water, if any).

Run bunker fuel centrifuge (if no engine running).

Start the Pre-lubricating oil pump.

Open the indicator cocks in the cylinder heads and rotate the engine several

times with the turning gear to make sure that no water, oil, or fuel has collected in

the cylinder.

Switch “OFF” the JW and IC heaters and switch-off the injector and jacket water-

circulating pumps.

Switch “OFF” the turning gear motor, disengage the turning gear, and lock the

operating lever.

96

Start-Up Procedure

Energize main power supply for the engine alarm.

Start up the following and adjust the pressures:

Pre-lubricating oil pump (manual position)

Diesel transfer pump

Fuel booster module

Nozzle cooling water pump

Jacket water pump

Fuel service pump

Check that the turning gear is disengaged and that the operating lever is locked.

Open all the indicator cocks.

Check starting air tank pressure gauge for the proper pressure of 25 to 30 bar.

Set the governor load limit to “0” position, and rotate the speed setting knob for at

least five [5] revolutions from zero.

Set the governor speed droop to “40” position.

Move each individual fuel pump rack in and out a few times to ensure rack is free

and not binding.

Press the emergency stop button.

Open the starting air valve.

Get clearance and “GO” signal with Shift Supervisor On-duty for startup activation.

97

Gradually unload (300 KW/min) the generator to avoid extreme thermal

stressing.

Open/trip the generator circuit breaker just before the KW-hr meter reaches 200

KW.

Let the generator run for at least 10 to 15 minutes to cool down the engine.

Set alarm power switch to “DISABLE” position.

Bring down the engine speed gradually and press the emergency stop button.

Open all indicator valves to release air from the cylinders. The engine should

stop running after 20 to 30 seconds.

Push control buttons of the following to “OFF” position.

Raw water pump

Cooling tower fan motor

Jacket water pump

njector cooling water pump

Switch “OFF” the chemical feed pump

Close the starting air main valves.

Switch “OFF” the pre-lube pump.

Switch “OFF” main power supply of ECP.

Stopping Procedures

98

MAINTENANCE PROCEDURES

The maintenance work to be carried out on the engine at regular

intervals is described in the maintenance schedule and is to be understood as

a guide. The maintenance intervals are dependent on the mode of operation

and load as well as on the quality of the fuel used.

Precautionary Measure For Maintenance Work

Prior to carrying out any maintenance work on the engine (especially

on the running gear), the following precautions have to be taken.

Pull out the Vacuum Circuit Breaker of generator engine under maintenance to

avoid accidental closing.

Installation of automatic control: Put automatic control switch to “OFF” position.

Close stop valves of starting air receivers.

Open all indicator cocks on the cylinder heads and leave in this position until

maintenance work is completed.

Engage turning gear (gear pinion must bee in engage position) and lock the

lever.

In case the engine had to be stopped due to overheated running gear

or bearings, wait at least 10 minutes before opening the crankcase doors.

99

Recommendations For Carrying Out The Work

Prior to turning the crankshaft with the turning gear, make sure that no loose

parts, tools or devices can get jammed.

When carrying out maintenance works, use the tools and devices intended for

the work.

Tools and devices should be ready prior to use and be in perfect conditions.

Hydraulic tools are to be checked from time to time for tightens and perfect

functioning.

All work must be done carefully, observing utmost cleanliness.

Where openings appear after certain parts have been removed, pipelines, oil

holes, etc., they must be temporarily closed off in order to prevent entry of any

dirt into the engine.

All parts overhauled during the course of servicing have to be checked for

perfect functioning before reinstalling back into service.

Pipes that have been removed have to be checked for tightness after refitting.

Clearances of moving parts must be checked periodically. Should the maximum

permissible values have been reached or exceeded, these parts must be

replaced.

When tightening studs, nuts or bolts, the utmost care must be taken not to

damage their threads and that they can be screwed in by hand until metal-to-

metal contact is obtained. The specified lubricants are to be used.

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