wartsilla power plant 6.3mw x 3

8/10/2019 Wartsilla Power Plant 6.3MW X 3

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TECHNICAL SPECIFICATION

FOR

3 SETS VASA 18V32

HEAVY FUEL GENERATING SETS


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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.......................................................................................................25A.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 TYPE OF THE PLANT

The proposed stationary power plant will be designed for base load application and is

intended for electricity production in parallel operation with public supply system.

Waste heat from the prime movers are utilized to produce thermal energy in the form of

steam.

The power plant will be designed for utilizing Heavy Fuel Oil as the main fuel with Light

Fuel Oil as standby fuel.


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A.0.2 PLANT MAIN DATA AND CONDITIONS

The power plant is equipped with three (3) Diesel Generating set(s) of the type Wartsila

Vasa 18V32, as prime mover.

Plant Gross Performance

Electrical production 18900 kWe

23625 kVA, power factor 0.8

Plant Ratings

Voltage 6.9 kV

Frequency 60 Hz

Auxiliary voltage 440 V AC, 3phase, 4 wire

110 V DC

Ambient Conditions

The equipment will be designed and constructed for operation at the extreme site

conditions of:

Ambient temperature, max. 39 oC

Ambient temperature, min. 10o

CEngine room air temperature, max. 10 oC above ambient temperature

Engine room air temperature, min. 0 oC

Altitude, max. 100 m a.s.l.

Water temperature to charge

air cooler, max. 38 oC

Wet bulb temperature, max. 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 reportingfollow-up, incentives, etc. schemes, thus laying the foundation for long term successful

operation of the plant.

A.0.4 CODES AND STANDARDS

The design and manufacturing of the plant are made according to following codes and

standards:

Mechanical system relevant ISO and DIN standards

Electrical system IEC


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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 Vee form

Number of cylinders 18

Cylinder bore 320 mm

Stroke 350 mm

Speed 720 rpm

Mean piston speed 8.4 m/s

Compression ration 13.8:1

Mean effective pressure 21.3 bar

Swept volume per cylinder 28.15 dm3

Number of valves 2 inlet valves

2 outlet valves

Direction of rotation faced towards flywheel Clockwise

Engine shaft output 6660 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 187 g/kWh

85% load 185 g/kWh

Lube oil consumption 0/8 0.3 g/kWh calculated at 100% load.

NOTE!: Net consumption, not including leakage and treatment losses.


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SPECIFICATION OF THE ENGINE

Fuel Oil System

The Wartsila Vasa 32 engine is designed for continuous operation on heavy fuel oil (HFO)

as well as light fuel oil (LFO). A preheated engine can be started directly on HFO

provided that the external fuel system has the correct temperature and pressure. The

engine can also be stopped on HFO although the external system has to stay in operation

i.e. fuel must be circulated through the stopped engine continuously for heating purposes.

The internal fuel system comprises the following equipment:

- Low pressure pipes make of steel

- High pressure pipes, double wall with common leak alarm

-

Injection pumps, individual for each cylinder

- Fuel injector in each cylinder

Lubricating Oil System

The lubricating oil system is lubricating the bearings and the cylinder liners in the engine.

Furthermore, the lube oil is also cooling the piston tops. The Wartsila Vasa 32 engines

have a wet sump oil system.

The internal lubricating oil system comprises the following equipment:

- Pipes made of steel

- Oil sump of wet type

- Engine driven main lube oil pump with pressure regulating valve

- Two by-pass centrifugal filter

- Start up / running in filters

- Non-return valves in oil supply pipes


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Starting Air System

All Wartsila Vasa 32 engines are started by means of compressed air with a nominal

pressure of 30 bars. The start is performed by direct injection of air into the cylinders

through the starting air valves in the cylinder heads. The V-engines are provided with

starting air valves for cylinders in the A-bank only. The master starting air valve can be

operated both manually and electrically.

The compressed air system for operation of the starting fuel limier and the

electropneumatic overspeed trip have their own connections to the external starting air

system.

The internal starting air system comprised the following equipment:

-

Pipes made of steel

- Starting air master valve

- Valve for electropneumatic overspeed trip

- Solenoid valve for fuel limiter

- Start blocking valve to prevent starting when turning gear is engaged

- Starting air distributor

- Starting air valves in each cylinder head (only A-bank cylinders in V-engines)

- Fuel limiter

-

Air container for emergency stop system- Pneumatic stop cylinder at each injection pump

- Booster for speed governor

- Flame arrestors

- Air filter for control air

Cooling Water System

The engine s cooling system (primary circuit) is divided into two circuits, the hightemperature circuit (HT) and low temperature circuit (LT). The HT-circuit is cooling the

cylinders, the turbocharger(s) and in engines equipped with split charge air coolers, also the

first stage of the charge air. The LT-circuit is cooling the second stage of the charge air

and the lube oil circuit through lube oil heat exchanger.

The internal cooling water system comprises the following equipment:

- Pies made of steel

- Engine driven pump for LT cooling circuit

-

Engine driven pump for HT cooling circuit

- Non-return valves after circulating pumps


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Combustion Air System

The compressor side of the turbocharger(s) is blowing air into the cylinders via the cooler

for the combustion process. The engine is equipped with one turbocharger per cylinder

bank. The turbocharger is of axial turbine type, facilitating exhaust gas energy to make

combustion.

For cleaning the compressor a washing system is included. The washing is carried out

during operation at regular intervals by means of fresh water injection.

The internal combustion air system comprises the following equipment:

- Compressor on the turbocharger

- LT-charge air cooler

-

Cleaning device for the compressor

Exhaust Gas System

The engine exhaust gas pipes are fully protected by an insulation box. Metal bellows are

fitted in the pipe system as well as between the turbocharger and the exhaust discharge pipe

system. The pipes are fixed by a bracket, but they are free to move axially.

The internal exhaust gas system comprises the following equipment:- Exhaust gas pipes with bellows

- Flexibly mounted insulation box

- Turbine on the turbocharger

- Turbine washing system

Speed Regulating System

Speed control of the engine is provided by using an electronic governor and a hydraulicactuator mounted on the engine. Speed setting switches are mounted in the control panel.


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Control System

The engine is provided with the following control and protection equipment.

- Pneumatic starting fuel limiter

-

Electro-pneumatic overspeed device for automatic stop of the engine, operating

independently of the speed governor

- Mechanical overspeed device for automatic stop of the engine, operating

independently of the speed governor

- Speed measuring system, including magnetic pick-up for engine speed and

turbocharger speed

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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Flexible mounted instrument panel on the engine including

- Tachometer with selector switch for engine or turbocharger speed

- Running hour counter

- Manometer with damper and check valve for

Fuel oil before engine

Lube oil before main bearings

HT-water before engine

LT-water before engine

Charge air in the air receiver

Starting air

Sensors for Alarm and Monitoring

One set of sensors fitted on the engine to be connected to an alarm and monitoring unit in

the control board specified in section A4.6.

Other Included Items

- Flywheel with fixing bolts

- Electrical motor driven turning device

-

Counter flanges for pipe connection- Crankcase safety valves with flame trap

- Indicator valves in the cylinder heads

- Safety valves in cylinder head

- Terminal box for electric cables

- The engine has one coat of priming paint and one coat of finishing paint

Technical data for pumps, built on the engine

HT-water circulation pump 210 m3/h 2.5 bar + static

LT-water circulation pump 210 m3/h 2.5 bar + static

Lubricating oil pump 123 m3/h 5.0 bar


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EXTREME LIMITS FOR OPERATION MEDIA

The diesel engines are designed and developed for continuous operation on operation

media as described below. Note, that those are extreme limits for Wartsila Diesel engines.

More detailed information about actually used operation media can be found under each

system description.

LIGHT FUEL OIL (LFO)

Viscosity, min (cSt at 40 oC) 2.8Viscosity, max. (cSt at 40 oC) 14.0Density, max. (at 15oC) (g/ml) 0.92Conradson carbon residue, max. 3.0Sulphur, max. (% mass) 2

Vanadium, max. PPM 100Sodium, max. 0Ash, max. (% mass) 0.05Water, max (% Vol.) 0.30Water before engine, max (% Vol.) 0.Asphaltenes, max. -Flash point, closed pesky-Martens, min (oC) 60Pour point, upper max. (oC) 6Aluminum + silicon max. (mg/kg) 25

HEAVY FUEL OIL (HFO)

Viscosity, max. (cSt at 100 oC) 5Density, max. (at 15oC) (cSt at 50 oC) 730Conradson carbon residue, max. (g/ml) 1.010Sulphur, max. (% mass) 22Vanadium, max. (% mass) 2.0Sodium, max. (mg/kg) 100Ash, max. (mg/kg) 20*)Water, max. (% mass) 0.05Water before engine, max. (% Vol.) 1

Asphaltenes, max. (% Vol.) 0.3Aluminum + silicon max. (% mass) 14Flash point, closed Pensky-Martens, min (mg/kg) 80Pour point, upper max. (oC) 60CCAI-number, max. (oC) 30

*) The maximum sodium content is related to the actual vanadium content in the fuel.


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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. 140 cSt at 40oC

max. 15 cSt at 100oC

SAE 40, max. 212 cSt at 40oC

Max. 19 cSt at 100oC

Flash point, open cup, min. -50 oC from nominal value

min 170 oC

Water, max. 0.5 %

BN 15-40 *)

Insolubles, max. 2 %

*) Required alkalinity is depending on the used fuel oil.

ENGINE COOLING WATER

Corrosion inhibiting additives must be used in the engine cooling water. Only additives

of the brand and types approved by Wartsila Diesel are allowed to be used. The additivemanufacturer s dosage, pH, and testing recommendations shall be followed.

If a nitrite based corrosion inhibitor is used, the aim should be to keep a nitrite (NO2)

content of about 1500 mg/l, calculated as nitrite. The pH shall be between 8.5 and 9.5.

In emergency cases the cooling water can be treated by addition of 5 kg/m3sodium nitrite

(NaNO2). To obtain a pH of about 9, add diluted caustic soda (sodium hydroxide, NaOH)

if necessary.


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Limits for engine cooling (primary circuit), turbine washing, and separator operating water:

pH at 25oC >7

Conductivity at 25oC (mS/m)


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A.1.2 GENERATOR

3 Self-cooled 3-phase brushless, salient pole type, synchronous generator(s)

Nominal output 7875 kVa

Power factor 0.8Voltage 6900 V, adjustment range 5%

Current, In 658 A

Frequency 60 Hz

Speed 720 Rpm

Runaway speed 864 Rpm

Efficiency at rated output, voltage and p.f. 0.8: 96.4 %

Continuous short circuit current About 3 x In

Insulation class / temperature rise F/F

Enclosure IP21

Standard IEC34

Shaft and bearing

The generator is horizontally mounted and provided with two bearings.

Cooling

The generator is self cooled with a shaft mounted fan which takes the cooling air from the

engine room and blows it through the generator.

Terminals

The six stator winding ends are brought to the terminal boxes on the generator sides.

Damper winding

The generator is provided with a damper winding for parallel operation with each other andwith separate grid.

Brushless excitation system

An exciter mounted in the generator supplies the excitation power for the brushless main

machine through a diode bridge. The control power for the exciter is supplied through an

automatic Voltage Regulator.


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Automatic voltage regulator

The voltage regulator will be a completely solid state type for control of generator voltage

by means of controlling the exciter field. The regulator will control the generator exciter

field as required to maintain a constant and stable generator output voltage within +/- 0.5%

of nominal for all generator steady state loads from no load to full load including a 5%

variation in frequency and the effects of field heating.

The regulator will have the capacity to adjust the generator output voltage between a

minimum of 95% of nominal volts (open circuit) and a maximum of 105% of nominal (full

load).

Accessories

- 6PT-100 elements in stator winding

- PT-100 element for bearing

- Anti condensation heater

- Automatic voltage regulator

- Current transformer for AVR


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A.1.3 COMMON BASE FRAME

3 Common base frame(s) of steel plates for the engine and the generator

A.1.4 ELASTIC MOUNTING

3 Sets of steel spring elements 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 MECHANICAL AUXILIARY SYSTEM

The proper function of the DG-set is dependent on the mechanical auxiliary systems. The

proposed systems have been optimized for the particular plant. The function of the

systems are to provide the engine with fuel oil, lubricating oil, starting air, cooling water

and charge air at required quantity and quality as well as to dispose of exhaust gases in a

proper manner.

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.

A.2.1.1 LIGHT FUEL OIL (LFO) SYSTEM

Light Fuel Oil System is used in case of operation disturbances and flushing of the system

before maintenance work, before longer stoppages and during start up when the HFO

system is not heated to operation temperature.

Storage, settling and day tank to be supplie d by the purchaser.

1 Set of equipment for day tank including

- - level switches or indicators and alarms for high and low fuel level.


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A.2.1.2 HEAVY FUEL OIL (HFO) SYSTEM

The Heavy Fuel Oil System is the main fuel oil system. The engine can be started andstopped at heavy fuel, provided that operation temperature is maintained. The system isdesigned for a fuel viscosity of 424 cSt/50oC and consists of the following equipment:

Storage, settling and day tank to be supplied by the purchaser.

1 Transfer pump unit

The function of the transfer pump unit is to pump fuel oil from the storage tanks to thebuffer tank. Transfer pumps and other components are built on a steel frame, whichforms one compact unit.

1 Separator unit(s) including

Centrifugal separators are installed to remove fuel contamination that are harmful to thediesel engine. Both water and solid can be effectively removed. Before entering the daytank the heavy fuel oil is purified by a centrifuge separator.

2 HFO Feeder / Booster unit(s)

The function of the fuel feed system is to supply the engine(s) with cleaned fuel of therequired flow, pressure and viscosity. The main components are the feeder pumps, the

booster pumps and the heater. The feeder pump supplies the correct flow of fuel fromday tank to the booster pump, booster pump rises the pressure and flow to the requiredlevel. The heater maintains a temperature corresponding to an injection viscosity of16-24 cSt.

3 Pump and filter unit(s)

The pump and filter unit are located between the booster and the engine. The unit is

protecting the engine by a last filtration. The pump provides the engine with the rightfuel quantity and pressure in installations were the booster unit is serving more than oneengine.

1 Return fuel oil unit(s)

The clean leak fuel is drained to the return fuel tank, and further pumped to the buffer tank.

2 sets of equipment for setting and day tank including

- level switches or indicators and alarms for high and low fuel level.

Note:The heavy fuel oil outlet temperature from the storage tank have to be 50oC, or 10oC above

pour point.


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A.2.2 LUBRICATING OIL SYSTEM

Lubrication oil system provides required lubrication for all moving parts on the engine. It

consists of engine related lubrication system and plant lubrication oil system, which serves

the whole power plants operation.

A.2.2.1 ENGINE LUBRICATING OIL SYSTEM

The lubricating oil is pumped from the oil sump by the main lube oil pump. The total

lube oil flow is cleaned in the fine filter and 23% of it passes through the centrifugal oil

filter. Before reaching the engine the lube oil enters the lube oil heat exchanger cooled by

the LT cooling water. The temperature of the lube oil is regulated by a three-way

thermostatic valve.

From the oil sump the lube oil is continuously pumped by the pump built on the separator

unit to the separator where water and solids are separated from the lube oil, and the cleaned

oil is returned back to the oil sump.

3 Lube oil separator unit(s)

The separators are dimensioned for continuous separation. Each engine has its own

separator unit.

3 Lube oil cooler(s)

The lubricating oil heats during operation and must therefore be cooled. In full load the

temperature rises up to 75-80oC. Lube oil cooler is plate heat exchanger type cooler.

3 Pre lube oil pump(s)

Before the engine is started the complete oil system must be filled and the engine

adequately primed by the prelubricating pump. The prelubricating pump is an electrically

driven pump equipped with a built-on overflow.

3 Find filter(s), fineness 0.015 mm

The fine filter unit consists of four filter chambers of full flow type. Normally all filters

are in use but during operation one filter at a time can be closed off and cartridges and be

changed. The fine filter unit(s) includes also differential pressure indicator(s).

3 Thermostatic three-way valves

The thermostatic valve has to mix warm and cold lubricating oil to obtain the right

temperature before entering the engine.


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A.2.3 COMPRESSED AIR SYSTEM

Compressed air is needed in the power plant for starting of the engines, as control &

instrumentation air and also as working air for tools, blow guns etc. The required amount

of air is produced in the starting air unit and in the control & instrumentation air unit.

The two air systems can be interconnected so that the starting air unit, in case of failure in

the control & instrumentation air unit, can deliver air also to control and instrumentation

equipment.

A.2.3.1 STARTING AIR SYSTEM

The starting air is produced by the two starting air compressors on the starting air unit.

The 30 bar air coming from the starting air unit is stored in starting air bottle(s) unit it is

used for starting the engine(s). The power plant starting air system consists of the

following main equipment:

1 Starting air unit(s)

3 Air bottles, 500 l, 30 bar, equipped with all necessary accessories.

European pressure vessel inspection certificates will be given to the purchaser.

A.2.3.2

CONTROL AND INSTRUMENTATION AIR SYSTEM

The control and instrumentation air is produced by the compressor of the control &

instrumentation air unit. The compressed air is stored in the built-on air bottle unit it is

distributed to the different consumers. The power plant control and instrumentation air

system consists of the following main equipment.


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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.

A.2.4.1 ENGINE COOLING SYSTEM

The engine itself is cooled by two separate water circuits. The high temperature circuit

(HT) is cooling charge air (in case two stage charge air cooler is used), cylinder heads and

cylinder liners. The low temperature circuit (LT) is cooling the charge air and lubricating

oil. Both circuits are connected to a heat exchanger which is cooled by cooling tower.

3 Open type expansion vessel(s) for HT/LT cooling water circuit

Including level indicator(s) and alarm(s) on the tank(s) for low water level.

3 Common central cooler(s)

The central cooler is of plate heat exchanger type. The heat exchanger is common for

both LT- and HT- water circuit. Via the central, cooler heat is transferred from engine

cooling system to secondary cooling system.

3 Preheating unit(s)

Water in the HT-circuit has to be preheated before start of the engine. A heater circuit

with a pump and heater is connected before the engine. The preheating circuit is provided

with a non-return valve to force water to flow in the right direction.

6 Thermostatic three-way valve(s)

The thermostatic valve for LT/HT circuit controls the outlet temperature of the water andthey are direct acting type. If operating temperature of the engine is too low, cooling

water is bypassed back to engine.


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A.2.4.2 SECONDARY COOLING SYSTEM

Secondary cooling system provides equipment for engine secondary water circulation

cooling. Equipment in secondary side can be connected to several engines and that s why

this system is also called as common or plant cooling system.

3 Cooling towar(s) (Purchaser supply)

The function of the cooling tower is based on evaporation heat. The hot water is cooled

by the upward airflow and pumped back to the heat exchangers from the cooling tower

basin.

Preliminary data, each engine:

Capacity 4900 kW

Outlet temperature 32oC

Flow 288 m3/h

3 Cooling tower pump(s) (Purchaser supply)

Pump Capacity 288 m3/h 2.5 bar

1 Maintenance water tank with an electrical motor driven discharge pump

The engine cooling water can be quickly drained to the tank in case of maintenance.Treated cooling water can thus be pumped back into the engine and reused after

maintenance. Water tank with a pump is common for several engines.


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A.2.5 CHARGE AIR SYSTEM

3 Set(s) of dry type, intake air filter(s)

The dry type filter is provided with a vertical weather louver and 1-stage glass fibre filter.

3 Set(s) of intake air silencer(s)

The noise attenuation of the silencer is 9-30 dB(A) (125-8000 Hz)

3 Set(s) of expansion bellows for intake air pipes

A.2.6 EXHAUST GAS SYSTEM

3 Exhaust gas silencer(s)

The absorption type silencer is equipped with a spark arrester. It is also provided with a

soot collector and water drain. The silencer can be mounted horizontally or vertically and

the noise attenuation is 35 dB(A).

3 Set(s) of expansion bellows for exhaust pipe


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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: Apparatus of secondary circuit:1 SF6 or vacuum circuit-breaker3 Current transformers2 Voltage transformers1 Earthing switch1 Cable transformer for earth fault

3 Ammeters1 Miniature circuit-breaker1 Breaker control switch1 Auxiliary relay

2 Neutral earthing cubicle(s)

1 Neutral grounding resistor 400A1 Disconnector1 Current transformer (single phase)

1 Busbar tie breaker cubicle(s), rated current 2000 A

1 Bus coupler SF6 breaker3 Current transformers


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2 Outgoing cubicle(s), rated current 3150 A

Apparatus of main circuit:

Apparatus of main circuit: Apparatus of secondary circuit:

1 SF6 or vacuum circuit-breaker3 Current transformers2 Voltage transformers1 Earthing switch1 Earth fault relay1 Voltmeter + selector switch1 3-phase independent time-lag

overcurrent relay and short circuitprotection relay

3 Ammeters1 Miniature circuit-breaker1 Breaker control switch1 Auxiliary relay

1 Station transformer cubicle, rated current 630 A

Apparatus of main circuit: Apparatus of secondary circuit:1 Circuit breaker or fuse load

breaker with tripping coil3 Current transformers1 Earthing switch1 3-phase independent time-lag

overcurrent relay andshort circuit protection relay

1 Earth fault relay1 Breaker control switch1 Tripping coil

2 Busbar measuring equipment

3 Voltage transformers3 Lightning arresters (one per phase)1 Under frequency protection1 Under voltage protection


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A.3.2 STATION SERVICE SYSTEM

Station service system is a common name for equipment to generate and distribute low

voltage electricity for power station electrical consumers and to enable auxiliaries

continuous and reliable operation. The system is connected to the main switchgear via

high voltage cables and station circuit breaker.

1 Station low voltage switchgear (auxiliary services)

Steel-sheet enclosed cubicle-type switchgear including supplies for the station motors andother apparatuses of the power plant. External protection class of the low voltageswitchgear is IP3x.

The switchgear consists of the following equipment:

Incoming feeder(s) with

1 Main switch1 Voltage meter with selector switch3 Ammeters

Fused outgoing feeders for local control panels

Motor starters direct on line for supplied electrical motor

Starters contain:- MCB or MCCB breakers- Contactor- Thermal overload relay- Control switch- Signal lamps for motor run and fault- Terminal blocks

3 Local control panel(s)

The local control panel is used to control the engine mounted electrical motors and heaters

of the DG-set. It is also equipped with indicating lamps and an alarm panel. It shouldbe placed close to the DG-set. Panel controls following motors and heaters:

- Generator anticondensation heaters- Prelube oil pump- Fuel booster pump- Turning gear motor- Preheating circulating pump- High temperature cooling circuit preheaters- Air filters (if motorized)- Outlet socket 16A


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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 Lead Acid

Size 75 Ah/10h

Voltage (DC) 110 V

2 Charger(s)

Charging current 12 A

1 Steel sheet enclosed distribution switchgear board

- Battery main switch- LCD display in the door of the system panel to measure output and setting

variables (voltage and current) and indication of alarm status- 10 pcs 20A MCBs spare feeders


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A.4 AUTOMATION, MONITORING AND SUPERVISION

A.4.1 CONTROL AND AUTOMATION SYSTEM

General

The control and automation systems are designed for safe, reliable, efficient and easyoperation of the power plant. The system consists of DG-set and auxiliary controls,operator s and process stations, engine and field instrumentation and data transmissionsystem. Engine output and speed of rotation are controlled by speed control, which isdesigned to operate in speed droop control and base load control (kW-control). Generatorreactive power and line voltage are controlled by automatic voltage regulator (AVR),which is designed to operate in voltage droop control and power factor control.

Central panel and an operator s station are located in the control room and engine localpanel is placed close to the engine and auxiliary local panels are attached to respective

units.

An engine is started, stopped and controlled with push buttons and switches at the centralcontrol panel in the control room. The operator can select either manual or automaticoperating mode for the DG-set thus enabling flexible control over the DG-set. Normallythe auxiliary systems are designed to operate automatically using level and pressureswitches etc., but starting up and shutting down of auxiliary processes requires manualoperator control at local control panels.

The operators will be able to monitor essential power plant functions at the operator sstation. The system uses PLC logic and conventional relay techniques to derive

information from engine and field instrumentation. The information is collected byenginewise process stations and one power plant common process station and then passedon the operator s station via a control network level us.

Panes are steel enclosed cubicle type panels with enclosure class IP2x and they areintended for indoor mounting.

Equipment is named and coded according to Wartsila Diesel coding of equipment in powerplants.

Central control panel common section

The common section contains power plant control functions. It contains the commonPLC system, the synchronizing equipment, the powerstation mimic and an alarmannunciation unit.

The synchronizing meters include a double voltage meter, a double frequency meter and asynchroscope with a synch check relay. Switches for synchronizing mode selection,speed/frequency increase/decrease control and voltage increase/decrease control areincluded as well as a push buttons for breaker close control. An autosynchroniser

performs the synchronizing in automatic mode, but the operator has the possibility to

synchronize breakers manually.


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The mimic contains the power station bus and position indicators for generator breakersand synchronisable breakers with synchronizing order push buttons.

The common section is typically located at the left end of the central control panel facingthe front.

Central control panel enginewise section

Each engine has one enginewise section in the central control panel. This sectioncontains essential meters, control and operation switches and protection relays for theDG-set.

The meters include three ammeters, one voltage meter with a selector switch for selectingany of the three line-to-line voltages, an active power meter with energy metering, areactive power meter, a power factor meter, a frequency meter, a speedometer with aselector switch for selecting the engine speed or turbocharger speed for display and arunning hour meter.

The control switches include a master switch for selecting manual or automatic operatingmode and manual operation switches (engine and generator control mode switches,increase/decrease controls and synchronizing selection). It also contains push buttons forstarting and stopping, breaker open and close control as well as breaker trip and engineshutdown reset.

The protection relays include functions for reverse power, overvoltage, overcurrent andground 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 factoryinstalled to the respective units. They include control switches, push buttons andindicator lights for the local supervision and control of the auxiliary systems. They givemore detail information about the specific part of the plant and allow the control of theauxiliary unit.

Operators station

The operator s station is used for monitoring the power plant. It reads information fromprocess stations with a bus operating at control network level and visualizes theinformation in easy-to-read displays on the PC monitor. The operator s station alsoincludes the alarm listing and printing, reporting and trending. The extended automationsystem includes one operator s station with facilities for further expand.

The operator s station is based on a PC based SCADA software running in MicrosoftWindows NT or 3.11 Windows for Workgroups. The operator station includes a largemonitor, one matrix type printer for alarm printing, one black & white printer for reportingand one colour printer for trend display screen prints. The electricity to operator s stationhardware is supplied from an uninterruptible power supply.


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Information from the process stations is arranged into groups which are displayed as pageson 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 plantcommon system displays are formed based on project related equipment, however typicallythe displays include the power plant fuel system, starting air system and an electrical single

line diagram.

The operator s station stores data from all analogue monitoring points to hard disk. Thisinformation can be called up in the historical trends displays. The trend displays arescaled to show information from one minute up to one week back.

The operator s station reporting system includes the following reports; Plant and enginedaily to operation data (optionally shift report), consumption and production reports (day,month, year and multi-year reports, optionally week and shift reports), duration curve forengine load and fault code registration.

Process stations

The automation system includes one process station for each engine, which is referred asthe enginewise process station. This process station monitors the engine with the engineinstrumentation and performs alarm and shutdown functions which are needed for safeoperation of the engine. It also performs the engine automatic operation sequences suchas 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 theengine local panel and it is connected to the operator s station at control network level inorder to provide the operators an easy method for monitoring the engine operation. Theenginewise 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 plantcommon functions such as the fuel system or the starting air system. This station isreferred as the power plant common process station. It is normally located in the centralcontrol panel/common section and it is connected to the operator s station at the controlnetwork level.

Engine instrumentation

The engine instrumentation is connected to the local control panels and monitored in thecontrol room by operator station. The engine instrumentation includes analoguetemperature 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 valueslocally.

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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- LT-water temperature after charge air cooler- Charge air pressure- Temperature inside air receiver

Field instrumentation

The field instrumentation includes switches, analogue sensors and local meters. Theimportant status information and analogue measuring results are transferred to the controlroom and monitored by the operator s station. The tank level alarms, common alarms forHFO separator unit and booster unit, high differential pressures in lube oil and safety filterand return fuel oil pump start/stop indications are presented in the operator s station.More detail status information is shown in the local control panels. Analogue informationis available about the tank levels and the fuel viscosity.

The field instrumentation includes also local meters to show pressure, temperature andlevel values locally beside the measuring point. Description of them is presented incontext of each unit or equipment.


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A.5 HEAT RECOVERY SYSTEM

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


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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 11 bar(s)

Steam flow 8.4 kg/h

2 Feed water pump(s)

Feed water will be pumped from the feed water tank to the boilers and deliver it at the

appropriate pressure.

1 Condensate return tank(s) with condensate pump

The condensate from the steam consumers will be collected in the condensate return tank

and then transported by the condensate pump to the feed water tank.

1 Steam heater

The steam header is used to collect the steam from all boilers and to feed it onwards to the

steam consuming devices.

1 Blow down tank(s)

A periodical blow down of the boiler water to be done to remove some futile compounds,

the concentration of which otherwise will build up and cause lower evaporation capacity

and increased corrosion. The blow down water is led to the blow down tank. The tank isautomatically cooled by water when needed.

1 Set(s) of chemical dosing equipment

In order to prevent corrosion and sediment certain chemicals has to be added to the feed

water.

1 control panel

Control panel has all necessary components for controlling and operating the steamsystem, except the burner operation components that are installed in burner.


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3 Set counter flanges

For connecting the equipment to the piping system.

OPERATING WATER

A: Turbine cooling water, primary circuit

B: Cooling towers and heat exchangers, secondary circuit

C: Steam system, make up water

D: Steam system, boiler water

E: Hot water system, feed water

A B C D E

pH at 25C >7 8.5-9.5 10.5-12 8.5-9.5

Conductivity at 25C mS/m


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A.6 EMISSION CONTROL SYSTEM

A.6.1

SELECTIVE CATALYTIC REDUCTION (De-NOx) system

The equipment used for reduction of nitrogen oxides (NOx) is based on Selective Catalytic

Reduction (SCR). In SCR process, nitrogen oxides are reduced by injection of ammonia

mainly to nitrogen (N2, the major component of air) and water (H2O). The NOx valve after

the De-NOx system is 235 ppm-v (dry, 13 vol. -%O2) at 100% engine load. Site conditions

as specified in chapter A.0.2.

Aqueous ammonia (25 weight- % NH3) is used as a reduction agent.

The system includes:

3 SCR-catalyst reactors

- Reactor housing without insulation- Catalyst elements- Standard instrumentation- Manual sootblowing system

3 Ammonia water injection equipment

- Injection nozzle- Injection piping- Valves, flanges

1 Ammonia water feeding pump units

- Ammonia metering pump

-

Set of valves and instrumentation- On skid piping

3 Control panels

1 Emission monitoring system

The system measures NO and calculates the total NOx emissions in ppm at reference

oxygen content.


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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

wartsilla power plant 6.3mw x 3

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