48/60 STATIONARY POWER Project Guide for Diesel Power Plants
Project Guide for Diesel Power Plants Stationary Plants Status 07.2004
MAN B&W Diesel AG P.O.B. 10 00 80 D-86135 Augsburg Phone: +49-821-322-0 Telefax: +49-821-322-3382
Titelseite P.fm
e-mail:
[email protected] Internet: www.manbw.com
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Contents 1
2
Basic information ............................................................. 1 - 1 1.1
Power plants by MAN B&W Diesel ...................................................................
1-3
1.2
About the Project Guide....................................................................................
1-5
1.3
Power plant concept .........................................................................................
1-7
1.4
Selection of engine (25MW, 55MW, 105MW) .................................................
1 - 25
Engine................................................................................ 2 - 1 2.1
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2.2
3
Data concerning all engines .............................................................................
2-3
2.1.1
Historical development of MAN B&W Diesel engines ......................................... 2 - 3
2.1.2
Programme for works test of four-stroke engines............................................... 2 - 9
2.1.3
Earthing measures on Diesel engines and bearing insulation on generators.... 2 - 10
2.1.4
Engine Running-in ............................................................................................. 2 - 12
2.1.5
Acceleration times ............................................................................................. 2 - 15
2.1.6
Standard reference conditions .......................................................................... 2 - 17
2.1.7
Load application ................................................................................................ 2 - 18
2.1.8
Adjustment of output and power....................................................................... 2 - 23
2.1.9
Exhaust gas emissions ...................................................................................... 2 - 28
2.1.10
Generator plants in isolated operation .............................................................. 2 - 30
2.1.11
Turbo charger and charge air cooler ................................................................. 2 - 32
2.1.12
Jet Assist ........................................................................................................... 2 - 33
2.1.13
Condensate amount .......................................................................................... 2 - 35
Engine 48/60.....................................................................................................
2 - 37
2.2.1
Outputs, speeds and designations.................................................................... 2 - 37
2.2.2
Dimensions, weights and cross sections .......................................................... 2 - 40
2.2.3
Calculation of performance (Projedat) ............................................................... 2 - 43
2.2.4
Engine noise..................................................................................................... 2 - 45
2.2.5
Intake noise ....................................................................................................... 2 - 46
2.2.6
Exhaust gas noise.............................................................................................. 2 - 47
2.2.7
Planning data..................................................................................................... 2 - 48
2.2.8
Maintenance and spare parts ............................................................................ 2 - 51
2.2.9
Turbo charger .................................................................................................... 2 - 55
Quality requirements........................................................ 3 - 1 3.1
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Quality of lube oil for operation on gas oil and Diesel oil (MGO/MDO) ........
3-3
Page i
Quality of lube oil for heavy fuel oil operation (HFO) ......................................
3-7
3.3
Quality of engine cooling water......................................................................
3 - 11
3.4
Checking cooling water ..................................................................................
3 - 19
3.5
Cleaning cooling water ...................................................................................
3 - 23
3.6
Quality of raw-water in cooling tower operation (addtive and circulating water)
3 - 25
3.7
Quality of heavy fuel oil (HFO) ........................................................................
3 - 27
3.8
Quality of Marine Diesel Fuel (MDO) ..............................................................
3 - 37
3.9
Quality of gas oil/Diesel fuel (MGO) ...............................................................
3 - 39
3.10
Viscosity temperature-diagram......................................................................
3 - 41
3.11
Quality of intake air (combustion air).............................................................
3 - 43
3.12
Quality of water used in exhaust gas boiler plants.......................................
3 - 45
Genset ............................................................................... 4 - 1 4.1
5
Engine-related systems - engine V48/60 .........................................................
5-3
5.1.1
Lube oil system.................................................................................................... 5 - 3
5.1.2
2-circuit radiator cooling system ......................................................................... 5 - 8 5.1.2.1 High temperature (HT) cooling water circuit ...................................... 5 - 8 5.1.2.2 Low temperature (LT) cooling water circuit ..................................... 5 - 12 5.1.2.3 Nozzle cooling water circuit ............................................................. 5 - 17
5.1.3
Cooling tower cooling system ........................................................................... 5 - 20
5.1.4
Fuel oil system................................................................................................... 5 - 22
5.1.5
Combustion air system...................................................................................... 5 - 26
5.1.6
Exhaust gas system (downstream of the engine).............................................. 5 - 30
Engine-related modules and components..................... 6 - 1 6.1
Engine-related modules and components - data concerning all engines ... 6.1.1
Page ii
4-3
Engine-related systems ................................................... 5 - 1 5.1
6
Genset for engine V48/60 ..................................................................................
6-3
Selection of economic serial products and procurement of accessories (electric motors, pumps, strainer and filter, control valves, cooler/ heat exchanger) ............ 6 - 3 6.1.1.1 Electric motors ................................................................................... 6 - 3 6.1.1.2 Pumps ................................................................................................ 6 - 4 6.1.1.3 Strainer ............................................................................................ 6 - 15
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3.2
6.1.1.4 6.1.1.5 6.1.1.6
6.2
7
6.1.2
Radiator cooling system .................................................................................... 6 - 26
6.1.3
Cooling tower cooling system (forced- air- cooled) .......................................... 6 - 30
6.1.4
Combustion air system...................................................................................... 6 - 31
6.1.5
Exhaust gas system........................................................................................... 6 - 38
6.1.6
Cleaning system for fuel and lube oil ................................................................ 6 - 44
Engine-related modules and components engine V48/60 - for
6 - 47
6.2.1
Lube oil system.................................................................................................. 6 - 47
6.2.2
2-circuit radiator cooling system ....................................................................... 6.2.2.1 High temperature (HT) cooling water circuit .................................... 6.2.2.2 Low temperature (LT) cooling water circuit ..................................... 6.2.2.3 Nozzle cooling water circuit .............................................................
6.2.3
Cooling tower cooling system ........................................................................... 6 - 59
6.2.4
Fuel oil system................................................................................................... 6 - 62
6.2.5
Combustion air system...................................................................................... 6 - 65
6.2.6
Exhaust gas module .......................................................................................... 6 - 69
6 - 52 6 - 52 6 - 55 6 - 57
Plant-related supply systems.......................................... 7 - 1 7.1
7.2
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Filter ................................................................................................. 6 - 16 Temperature Control valves ............................................................. 6 - 22 Cooler/ Heat exchanger (HE) .......................................................... 6 - 23
7.3
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Plant-related supply systems - description for all plants ..............................
7-3
7.1.1
Lube oil supply system ........................................................................................ 7 - 3
7.1.2
Water supply and treatment system.................................................................... 7 - 5
7.1.3
Diesel oil supply system ...................................................................................... 7 - 7
7.1.4
Heavy fuel oil supply and treatment system........................................................ 7 - 9
7.1.5
Start / control air supply system........................................................................ 7 - 11
7.1.6
Engine preheating system ................................................................................. 7 - 13
Plant-related supply systems - drawings for 55MW plant...........................
7 - 17
7.2.1
Lube oil supply system ...................................................................................... 7 - 18
7.2.2
Water supply and treatment system.................................................................. 7 - 20
7.2.3
Diesel oil supply system .................................................................................... 7 - 22
7.2.4
Heavy fuel oil supply and treatment system...................................................... 7 - 24
7.2.5
Start / control air supply system........................................................................ 7 - 26
7.2.6
Engine preheating system ................................................................................. 7 - 30
Plant-related supply systems - drawings for 105MW plant.........................
7 - 33
7.3.1
Lube oil supply system ...................................................................................... 7 - 34
7.3.2
Water supply and treatment system.................................................................. 7 - 36
7.3.3
Diesel oil supply system .................................................................................... 7 - 38
7.3.4
Heavy fuel oil supply and treatment system...................................................... 7 - 40
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7.3.6
Engine preheating system ................................................................................. 7 - 44
Plant-related supply modules and components ........... 8 - 1 8.1
8.2
8.3
9
Start / control air supply system........................................................................ 7 - 42
Plant-related supply modules and components - description for all plants
8-3
8.1.1
Lube oil supply modules and components ......................................................... 8 - 3
8.1.2
Water supply, treatment modules and components ........................................... 8 - 5
8.1.3
Diesel oil supply modules and components........................................................ 8 - 7
8.1.4
Heavy fuel oil supply modules and components................................................. 8 - 9
8.1.5
Start / control air supply modules and components ......................................... 8 - 11
8.1.6
Engine preheating system ................................................................................. 8 - 13
Plant-related supply modules and components - drawings for 55MW plant
8 - 15
8.2.1
Lube oil supply modules and components ....................................................... 8 - 16
8.2.2
Water supply, treatment modules and components ......................................... 8 - 17
8.2.3
Diesel oil supply modules and components...................................................... 8 - 19
8.2.4
Heavy fuel oil supply modules and components............................................... 8 - 21
8.2.5
Start / control air supply modules and components ......................................... 8 - 23
8.2.6
Engine preheating modules and components................................................... 8 - 25
Plant-related supply modules and components - drawings for 105MW plant
8 - 27
8.3.1
Lube oil supply modules and components ....................................................... 8 - 28
8.3.2
Water supply, treatment modules and components ......................................... 8 - 29
8.3.3
Diesel oil supply modules and components...................................................... 8 - 31
8.3.4
Heavy fuel oil supply modules and components............................................... 8 - 33
8.3.5
Start / control air supply modules and components ......................................... 8 - 36
8.3.6
Engine preheating modules and components................................................... 8 - 38
External exhaust and boiler systems ............................. 9 - 1 9.1
External exhaust and boiler systems - description for all plants ..................
9-3
9.2
Exhaust gas treatment system - description for all plants ............................
9-4
9.3
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9.2.1
Selective catalytic reduction system (DeNOx)..................................................... 9 - 4
9.2.2
Desulphurisation system (DeSOx) ....................................................................... 9 - 6
9.2.3
Particulate Matter (PM) ........................................................................................ 9 - 9
Heat recovery system......................................................................................
9 - 11
9.3.1
Calculation of heat demand - for 55MW- plant ................................................. 9 - 11
9.3.2
Steam generation system - diagram ................................................................. 9 - 13
9.3.3
Thermal oil system - diagram ............................................................................ 9 - 15
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7.3.5
9.3.4
Hot water generation system - diagram ............................................................ 9 - 16
10 External exhaust and boiler modules and components 10.1
10.2
10.3
10 - 1
Exhaust modules and components - description for all plants...................
10 - 3
10.1.1
Main stacks and flow noise ............................................................................... 10 - 3
10.1.2
Bypass stack - Photograph of existing power plant ......................................... 10 - 8
Exhaust gas treatment modules and components -photographs of existing power plants 10 - 9 10.2.1
Desulphurisation (DeSOx) with NaOH- scrubber .............................................. 10 - 9
10.2.2
Desulphurisation (DeSOx) with limestone- scrubber....................................... 10 - 10
10.2.3
ESP for V48/60 ................................................................................................ 10 - 13
Heat recovery modules and components ...................................................
10 - 14
10.3.1
Exhaust gas boiler for steam generation ......................................................... 10 - 14
10.3.2
Exhaust gas boiler for thermal oil system........................................................ 10 - 15
11 Plant-related electrical systems ................................... 11 - 1 11.1
11.2
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11.3
Electrical system..............................................................................................
11 - 3
11.1.1
General design................................................................................................... 11 - 3
11.1.2
High voltage part ............................................................................................... 11 - 5
11.1.3
Step-up-transformer.......................................................................................... 11 - 6
11.1.4
Medium voltage system................................................................................... 11 - 11
11.1.5
Service transformer ......................................................................................... 11 - 15
11.1.6
Low voltage part .............................................................................................. 11 - 18
Generator / alternator....................................................................................
11 - 19
11.2.1
General design................................................................................................. 11 - 19
11.2.2
Mechanic part.................................................................................................. 11 - 20
11.2.3
Electrical part................................................................................................... 11 - 21
Control, monitoring and alarm system ........................................................
11 - 25
11.3.1
General design................................................................................................. 11 - 25
11.3.2
Control system ................................................................................................ 11 - 27
11.3.3
Engine.............................................................................................................. 11 - 30
11.4
Concept layout for MAN B&W Diesel standard scope ...............................
11 - 31
11.5
Single line diagram ........................................................................................
11 - 37
11.6
Lists for electrical systems ...........................................................................
11 - 39
11.6.1
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List of cables ................................................................................................... 11 - 39
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11.6.2
List of equipment ............................................................................................. 11 - 40
11.6.3
List of measuring points .................................................................................. 11 - 41
11.6.4
List of consumers ............................................................................................ 11 - 42
11.6.5
List of Electric motors...................................................................................... 11 - 46
11.6.6
List of measurement and control devices ....................................................... 11 - 47
11.6.7
List of signals................................................................................................... 11 - 51
11.7
Data sheets for electrical system.................................................................
11 - 53
11.8
Earthing and protection system ...................................................................
11 - 55
11.9
11.8.1
Earthing system ............................................................................................... 11 - 55
11.8.2
Protection ........................................................................................................ 11 - 63
11.8.3
Touch / step voltages evaluation..................................................................... 11 - 66
Lighting and small power system ................................................................
11 - 69
11.10 Drawings and documentation for electrical systems.................................
11 - 71
12 Tank farm ........................................................................ 12 - 1 12.1
Tank farm - description for all plants.............................................................
12 - 3
12.2
Tank farm - drawings for 55MW plant .........................................................
12 - 11
12.3
Tank farm - drawings for 105MW plant .......................................................
12 - 13
13 Plant Service and protection system ........................... 13 - 1
13.2
13.3
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Plant Service and protection systems- description for all plants ...............
13 - 3
13.1.1
Work air system ................................................................................................. 13 - 3
13.1.2
Fire detection and fire fighting systems ............................................................ 13 - 5
13.1.3
Waste treatment and disposal........................................................................... 13 - 7 13.1.3.1 Sludge and leakage treatment and discharge system .................... 13 - 7 13.1.3.2 Contaminated process water treatment and discharge system ...... 13 - 9
Plant service and protection systems- drawings for all plants .................
13 - 11
13.2.1
Schematic diagram treatment of contaminated process waters .................... 13 - 11
13.2.2
Components .................................................................................................... 13.2.2.1 Leakage oil/sludge module ............................................................ 13.2.2.2 Photograph of installed leakage oil/sludge module ....................... 13.2.2.3 Detail drawing for sludge pit (2 chamber) ...................................... 13.2.2.4 Detail sketch for sludge pit (3 chamber) ........................................
Plant service and protection systems- drawing for
55 MW plant ........
13 - 13 13 - 13 13 - 15 13 - 17 13 - 19
13 - 21
13.3.1
Work air system .............................................................................................. 13 - 22
13.3.2
Sludge-, leakage-, HFO treatment-
13.3.3
Heavy- fuel oil separator- module ................................................................... 13 - 29
and discharge system.......................... 13 - 26
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13.1
13.4
Plant service and protection systems - drawings for 105 MW plant ........
13 - 31
13.4.1
Work air system ............................................................................................... 13 - 32
13.4.2
Sludge-, leakage-, HFO treatment and discharge
13.4.3
Heavy- fuel oil separator - module .................................................................. 13 - 39
system .......................... 13 - 36
14 Buildings ......................................................................... 14 - 1 14.1
Descriptions for engines V32/40 and V48/60 ................................................
14 - 3
14.1.1
Power House ..................................................................................................... 14 - 3
14.1.2
Power House Ventilation system ..................................................................... 14 - 30
14.1.3
Power House crane ......................................................................................... 14 - 39 14.1.3.1 Sole plate 48/60 ............................................................................. 14 - 41
14.1.4
Pump House, fuel treatment............................................................................ 14 - 47 14.1.4.1 Ventilation of the separator room .................................................. 14 - 48
14.1.5
Unloading and weighting station ..................................................................... 14 - 51
14.1.6
Work shop and stores ..................................................................................... 14 - 53
15 Project engineering........................................................ 15 - 1 15.1
Minimum data for quotation of MAN B&W Diesel stationary power plant .
15 - 3
15.2
Engineering service for planning a power plant .........................................
15 - 15
15.3
Timetable and milestones .............................................................................
15 - 19
15.4
Piping with related fittings, seals, armatures..............................................
15 - 25
15.4.1
15.5
System - isometric - lube oil............................................................................ 15 - 31
Typical drawings generated from plant design ..........................................
15 - 33
15.5.1
Steel support construction .............................................................................. 15 - 33
15.5.2
Pipe- isometric................................................................................................. 15 - 35
15.6
Photoseries of existing power plants ..........................................................
15 - 37
15.7
Noise investigation ........................................................................................
15 - 43
15.8
Miscellaneous ................................................................................................
15 - 47
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16 Appendix ......................................................................... 16 - 1 16.1
Symbols ............................................................................................................
16 - 3
16.2
Marking instruction for power plant components ......................................
16 - 21
16.3
Code for accessories ....................................................................................
16 - 25
16.4
Abbreviations .................................................................................................
16 - 39
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16.5
Conversion of Units .......................................................................................
16 - 41
16.6
Flow rate and velocity diagram for liquids, gases and vapours ................
16 - 45
16.7
Calculation of the system resistance and adjustment of the centrifugal pump to the service point 16 - 47
16.8
List of MAN B&W drawings...........................................................................
16 - 51
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Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
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Basic information
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Power plants by MAN B&W Diesel
1.1
Power plants by MAN B&W Diesel
MAN B&W Diesel MAN B&W Diesel is the Diesel engine manufacturer who can look back upon the most years of tradition worldwide. Rudolf Diesel, inventor cooperating with MAN Augsburg works, developed the world’s first Diesel engine from 1893 to 1897. MAN B&W Diesel is thus considered as the "birthplace" of the Diesel engine. Thereafter, MAN concentrated on the production of stationary Diesel power plants. In 1904, MAN delivered the world’s first large Diesel power plant to Kiew. The MAN B&W Diesel parent works at Augsburg today concentrates • On the improvement and manufacturing of medium speed Diesel engines, and • On the planning and delivery of stationary Diesel power plants up to turnkey plants. With regard to the century-long tradition MAN B&W Diesel strives to optimise the products and to develop the best solution for the client with regard to technology and efficiency. Power plant concept The power houses and especially the foundation for the Diesel-generator-sets passed through historical developments. MAN B&W Diesel reengineered the power plant concept according to today’s and tomorrow’s demands. In the new concept all components, i.e. genset, mechanical accessories, pipes, cables and electric equipment, are positioned on one level within the power house.
• Fast and uncomplicated assembly and commissioning, • Stable and efficient operation during the entire life cycle of the system. The objectives were achieved by these measures: • Reduction of enclosed space for the power house, • Simple design of the structure, • Modular design and assembly to the greatest possible extent, • Prefabrication and delivery of ready to install Diesel-generator-sets and modules in the manufacture works, • Obtainment of tested, well-running concepts, • Obtainment of short manufacturing and delivery times for the Diesel power plants at acceptable investments. This new single-floor power plant concept, as seen in the following figure, is the standard concept. It is described in detail in this Project Guide. MAN B&W Diesel today offers different enginegenerator-sets for the single-floor power house. They are described in Chapter 4 "Genset", Page 4-1. When planning a power plant, MAN B&W Diesel requires the data given in Chapter 15.1 "Minimum data for quotation of MAN B&W Diesel stationary power plant", Page 15-3, from the client.
The design of the single-floor power plant focused on the following objectives:
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• Space-saving and service-friendly arrangement, • Simple and cost-effective design of the structure,
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Page 1 - 3
Power plants by MAN B&W Diesel
Cross-section of single-floor power house
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Figure 1-1
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About the Project Guide
1.2
About the Project Guide
Objective The Project Guide serves • To give the client information on MAN B&W Diesel power plants, and
• geodetic site altitude, • cooling system.
• To support the MAN B&W Diesel sales department to plan a power plant.
The Projedat computer program cannot be used externally.
The Project Guide is to assist the preparation of a power plant project and to give first information on the power plant design.
On example each, both fo rthe 18V 32/40 and the 18V 48/60 engine is included in Chapter 2.2.3 "Calculation of performance (Projedat)", Page 2-43 and Chapter 2.2.3 "Calculation of performance (Projedat)", Page 2-43, as visual demonstration material.
Described engines and plants The Project Guide describes power plants of three different sizes and comprising different engines. These are: • Power plant 25MW Comprising 3 x engine 18V 32/40 • Power plant 55MW Comprising 3 x engine 18V 48/60 • Power plant 105MW Comprising 6 x engine 18V 48/60 According to your needs, the Project Guide describes either • all above mentioned engines and power plants, or • one engine or plant of your interest. Projedat Projedat is an electronic computer program for the determination of engine planning data such as
PDS-Numbers The PDS-Numbers stated below each chapter headline refer to the "Produkt-Daten-Struktur" (product-data-classification) MAN B&W Diesel uses to organise its quotations. When receiving a MAN B&W Diesel quotation, you will recognise the PDS-Numbers. Engine versions Several MAN B&W Diesel engines are available as L-engines as well as V-engines. In the Project Guide, please note that the texts, tables and figures are marked as follows: • Letter "L" or "V" before the engine type The information is valid for the stated engine version only. Example: "Engine L 32/40". • No letter before the engine type
• site rating,
The information applies to both the L-engine and the V-engine, if existent.
• quantity of heat to be dissipated,
Example: "Engine 32/40".
• intake air quantity • axhaust gas quantity 0102-0101PA.fm
• ambient climatic conditions (minimum and maximum ambient temperatures)
• exhaust gas temperature depending on the site conditions, e.g.:
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Constrictions The Project Guide covers information on typical power plants. The data given is exemplary and not binding.
Page 1 - 5
About the Project Guide
The Project Guide does not substitute the detailed design, specifications and calculations of the project engineering for an individual engine or power plant. All information in the Project Guide is subject to change by MAN B&W Diesel without notice.
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The Project Guide is property of MAN B&W Diesel. It may not be reproduced, communicated or published without prior written consent by MAN B&W Diesel.
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Power plant concept
1.3
Power plant concept
Diesel power plants Usually, Diesel engines are used for stationary application in combination with generators for power generation. The area of application comprises ranges from the coverage of peak loads or basic loads in public mains supplies to isolated applications for industrial consumers. The favoured working material is the well-priced heavy oil, but engine operation with gas is also available. The MAN B&W Diesel medium speed fourstroke Diesel engines, types 32/40 and 48/60, cover a range of performance from approx. 4.3MW to approx. 18.9MW per genset. The four-stroke Diesel engine has several advantages as opposed to the two-stroke Diesel engine that recommend it for stationary application. It demands less space, smaller foundation and has lower investment costs. Generally, the power generation by power plants medium speed four-stroke engines is more cost-effective than that by power plants with slow speed twostroke engines. Thus, the power plant with fourstroke engines is amortised faster. From the abundance of power plants built by MAN B&W Diesel, three representative power plant sizes are presented in the following. These are: • Power plant 25MW Comprising 3 x engine 18V 32/40 • Power plant 55MW Comprising 3 x engine 18V 48/60 • Power plant 105MW
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Comprising 6 x engine 18V 48/60.
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Power plant concept
25MW power plant
Three dimensional view generated from plant design
Figure 1-2
Layout- example for 25 MW plant
Figure 1-3
Side view of power house - example for 25MW power plant
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1. Power house 2. Exhaust gas boiler plant 3. DeSOx plant 4. Radiator cooler plant 5. Tank farm 6. Pump house 7. Workshop store
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Power plant concept
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25MW power plant
Figure 1-4
Typical layout drawing (consisting of figure 1-4 to 1-5)
Cross section and view from above - example for 25MW power plant
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Power plant concept
Figure 1-5
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Typical layout drawing (consisting of figure 1-4 to 1-5)
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25MW power plant
Table for plant equipment and weights - example for 25MW power plant
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Power plant concept
25MW power plant - site plan
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TANKFARM DETAILS SEE CHAPTER 12
Figure 1-6
Site plan - example for 25MW power plant
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Power plant concept
55MW power plant
Three dimensional view generated from plant design
Figure 1-7
Power house and radiator cooler plant - example for 55MW power plant
Figure 1-8
View inside the power house
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1. Power house 2. Exhaust gas duct 3. Air intake 4. Chimney 5. Radiator cooler plant
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Power plant concept
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55MW power plant
Photograph of an executed power plant
Figure 1-9
Power house - example for 55MW power plant
Figure 1-10
Power house - example for 55MW power plant
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Power plant concept
Figure 1-11
Page 1 - 14
Typical layout drawing (consisting of figure 1-11 to 1-14)
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55MW power plant
Power house, sectional view - example for 55MW power plant
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Power plant concept
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55MW power plant
Figure 1-12
Typical layout drawing (consisting of figure 1-11 to 1-14)
Longitudinal section- example for 55MW power plant
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Power plant concept
Typical layout drawing (consisting of figure 1-11 to 1-14)
Figure 1-13
Power house, topview - example for 55MW power plant level above ± 0,00, level above + 6,50, level above +10,50.
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55MW power plant
Power plant concept
55MW power plant
Table for plant equipment and weights - example for 55MW power plant
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Figure 1-14
Typical layout drawing (consisting of figure 1-11 to 1-14)
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Power plant concept
55MW power plant- Site plan
TANKFARM DETAILS SEE CHAPTER 12 Site plan - example for 55MW power plant
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Figure 1-15
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Power plant concept
105MW power plant
Three dimensional view generated from plant design
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1) Power house 2) Exhaust gas duct 3) Air intake 4) chimney 5) Radiator cooler 6) Tank farm 7) Pump house Figure 1-16
Power plant with 3 x 55MW (165 MW)
Figure 1-17
View inside the power house (5 x18V 48/60)
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Power plant concept
Figure 1-18
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Typical layout drawing (consisting of figure 1-18 to 1-21)
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105MW power house
Power house cross section - example for 105MW power plant
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Power plant concept
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105MW power plant
Figure 1-19
Typical layout drawing (consisting of figure 1-18 to 1-21)
Longitudinal section of power house - example for 105MW power plant
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Power plant concept
Typical layout drawing (consisting of figure 1-18 to 1-21)
Figure 1-20
Power house - topview example for 105MW power plant, above level ± 0,00, above level + 6,5, above level + 20,50
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105MW power plant
Power plant concept
105MW power plant
Table for plant equipment and weights - example for 105MW power plant
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Figure 1-21
Typical layout drawing (consisting of figure 1-18 to 1-21)
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Power plant concept
105MW power plant- site plan
TANKFARM DETAILS SEE CHAPTER 12
Site plan - example for 105MW power plant
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Figure 1-22
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Selection of engine (25MW, 55MW, 105MW)
1.4
Selection of engine (25MW, 55MW, 105MW)
To select the number and type of engine necessary for the power plant, see Figure 1-23, Page 1-25.
Selection of engine
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Figure 1-23
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Selection of engine (25MW, 55MW, 105MW)
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Engine
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2
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Data concerning all engines
2.1
Data concerning all engines
2.1.1
Historical development of MAN B&W Diesel engines
The Diesel engine is a modern prime mover at a high state of development. At the Augsburg location, MAN B&W Diesel develops and builds large super-charged, medium speed four-stroke Diesel engines. The V 32/40 and V 48/60 engines, both used for the power plant concept "single-floor power house", are described in Chapter 2 "Engine", Page 2-1. The characteristics of the Diesel engine are:
Figure 2-1
• High efficiency, • Low fuel consumption, • High availability, • The ability to burn fuel of poor and poorest quality at - Reduced wear, thus long lifetime, despite high firing pressure. The following graphs show the development of the MAN B&W Diesel engines.
Development of mean effective pressure (left) and mean piston speed (right)
Mean effective pressure (mep):
Mean piston speed:
Engine 32/40.......................................... 24.9bar
Since, 1990 a mean piston speed of 10m/s is safely controllable in series due to the available materials and metallurgy.
Engine 48/60.......................................... 23.2bar
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In 1951 MAN B&W Diesel tested super-charging engines which is today state of the art.
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Data concerning all engines
Figure 2-2
Development of specific fuel oil consumption (sfoc) (g/kWh)
The combustion process was optimised by improved materials which allow • Higher firing pressure, • Improved combustion, • Reduced consumption, • Improved efficiency.
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In 1892 Rudolf Diesel mentioned, in his patent, a firing pressures of 250bar. Today, firing pressures of 220bar are achieved.
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Data concerning all engines
Figure 2-3
Wear rate improvements
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Despite maximum demands made on engines components, better wear rates and reductions in the times between overhaul can, and must be, achieved by using improved materials and material combinations.
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Data concerning all engines
Figure 2-4
Prime mover systems
Development of the efficiency of four-stroke Diesel engines
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The efficiency was improved due to utilisation of exhaust gas (Diesel combined cycle).
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Data concerning all engines
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Figure 2-5
Sankey-diagram
MAN B&W Diesel uses two-step charge air coolers. Thus, a bulk of the energy of the combustion air compressed in the turbocharger can be used for heat recovery at a high temperature level.
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Data concerning all engines
Figure 2-6
HFO operation with exhaust gas treatment and heat recovery
For exhaust gas treatment MAN B&W Diesel offers • NOx-reduction in selective catalytic reduction (DeNOx),
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• SOx-reduction in scrubber-plants (DeSOx).
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Data concerning all engines
2.1.2
Programme for works test of four-stroke engines PDS: 10 10 350, 20 30 70
Cons. No.
Engine rating
Operating time
LT cooling water temperature
% site rating
min.
°C (ISO)
1
100
60
25
2
100
30
According to site conditions
3
85
30
According to site conditions
Figure 2-7
Operating points to be considered during the acceptance test run
Acceptance test record • Service records for above load points in accordance with ISO Standard 3046-1. • Service records for load points 25%, 50%, 75% and 110% of previous test run measurement. • Records of starting attempts, governor testing and safety system testing of previous test run measurements. Remarks • Further load points can only be demonstrated during the acceptance test run (30 minutes each), if this is part of the contract. • After the acceptance test run, the components will be inspected, as far as this is possible without dismantling them.
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Components will only be removed on customer’s order.
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Data concerning all engines
2.1.3
Earthing measures on Diesel engines and bearing insulation on generators PDS: 70 50
General The use of electrical equipment on Diesel engines requires precautions to be taken for protection against shock current and for equipotential bonding. These not only serve as shock protection but also for functional protection of electric and electronic devices (EMC protection, device protection in case of welding, etc.).
Earthing connection on engine
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Figure 2-8
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Data concerning all engines
Earthing connections on the engine Threaded bores M12, 20 mm deep, marked with the earthing symbol have been provided in the engine foot on both ends of the engines. It has to be ensured that earthing is carried out immediately after engine set-up! (If this cannot be accomplished any other way, at least provisional earthing is to be effected right at the beginning.) Measures to be taken on the generator
0201-0301PA.fm
Because of slight magnetic unbalances and ring excitations, shaft voltages, i.e. voltages between the two shaft ends, are generated in electrical machines. In the case of considerable values (e.g. >0.3V), there is the risk that bearing damage occurs due to current transfers. For this reason, at least the bearing that is not located on the drive end is insulated on generators approx. > 1MW. For verification, the voltage available at the shaft (shaft voltage) is measured while the generator is running and excited. With unobjectionable insulation, this voltage corresponds to the voltage between “shaft” and “earth”. In order to protect the prime mover and to divert electrostatic charging, an earthing brush is often fitted on the coupling side.
Another possibility would be to measure the voltage between the shaft end on the free engine end and the generator casing, once the rated speed and the nominal voltage of the generator have been reached. If the measured voltage is lower than 0.5 V (alternating voltage), the generator manufacturer should be consulted. Earthing conductor The nominal cross section of the earthing conductor (equipotential bonding conductor) has to be selected in accordance with DIN VDE 0100, part 540 (up to 1000V) or DIN VDE 0141 (in excess of 1KV). Generally, the following applies: The protective conductor to be assigned to the largest main conductor is to be taken as a basis for sizing the cross sections of the equipotential bonding conductors. Flexible conductors have to be used for the connection of resiliently mounted engines. Execution of earthing At stationary plants, earthing has to be carried out by the party responsible for the construction of the plant.
Observation of the required measures is the generator manufacturer’s responsibility.
Earthing strips are not included in the MAN B&W Diesel scope of supply.
Consequences of inadequate bearing insulation on the generator, and insulation check
Additional information regarding the use of welding equipment
In case the bearing insulation is inadequate, e.g., if the bearing insulation was short-circuited by a measuring lead (PT100, vibration sensor), leakage currents may occur, which result in the destruction of the bearings. One possibility to check the insulation with the machine at standstill (prior to coupling the generator to the engine; this, however, is only possible in the case of single–bearing generators) would be to raise the generator rotor (insulated, in the crane) on the coupling side, and to measure the insulation by means of the Megger test against earth (in this connection, the max. voltage permitted by the generator manufacturer is to be observed!).
In order to prevent damage on electrical components, it is imperative to earth welding equipment close to the welding area, i.e., the distance between the welding electrode and the earthing connection should not exceed 10m.
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Data concerning all engines
2.1.4
Engine Running-in PDS: 230 110
Engines must be run in • during commissioning at site if, after the test run, pistons or bearings were removed for inspection and/or if the engine was partly or completely disassembled for transport, • on installation of new running gear components, e.g. cylinder liners, piston rings, main bearings, big-end bearings and piston pin bearings, • on installation of used bearing shells, • after an extended low-load operation (> 500 operating hours). Supplementary information Adjustment required Surface irregularities on the piston rings and the cylinder liner running surface are smoothed out during the running-in process. The process is ended when the first piston ring forms a perfect seal towards the combustion chamber, i.e. the first piston ring exhibits an even running surface around its entire circumference. If the engine is subjected to a higher load before this occurs, the hot exhaust gases will pass between the piston rings and the cylinder liner running surface. The film of oil will be destroyed at these locations. The consequence will be material destruction (e.g. scald marks) on the running surfaces of the rings and the cylinder liner and increased wear and high oil consumption during subsequent operation. The duration of the running-in period is influenced by a number of factors, including the condition of the surface of piston rings and the cylinder liner, the quality of the fuel and lube oil and the loading and speed of the engine. The running-in periods shown in Figure 2-9, Page 2-14, and Figure 2-10, Page 2-14, respectively, are, therefore, for guidance only.
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Operating media Fuel Diesel oil or heavy fuel oil can be used for the running-in process. The fuel used must satisfy the quality requirements (see Chapter 3 "Quality requirements", Page 3-1) and be appropriate for the fuel system layout. The gas that is to be later used under operational conditions is best used for running-in sparkignited gas engines. Dual-fuel engines are run-in in Diesel mode using the fuel oil that will later be used as pilot oil. Lubricating oil The lubricating oil to be used while running in the engine must satisfy the quality requirements (see Chapter 3 "Quality requirements", Page 3-1) relating to the relevant fuel quality. Attention! The lube oil system is to be rinsed out before filling it for the first time (see MAN B&W Diesel Work Card 000.03). Running-in the engine Cylinder lubrication During the entire running-in process, the cylinder lubrication is to be switched to the “Running-in” mode. This is done at the control cabinet and/or the operator’s panel and causes the cylinder lubrication to be activated over the entire load range already when the engine is started. The increased oil supply has a favourable effect on the running-in of the piston rings and pistons. After completion of the running-in process, the cylinder lubrication is to be switched back to “Normal Mode”. 0201-0401PA.fm
Preconditions
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Data concerning all engines
Checks During running-in, the bearing temperature and crankcase are to be checked • for the first time after 10 minutes of operation at minimum speed, • again after operational output levels have been reached. The bearing temperatures (camshaft bearings, big-end and main bearings) are to be measured and compared with those of the neighbouring bearings. For this purpose, an electric tracertype thermometer can be used as measuring device. At 85% load and on reaching operational output levels, the operating data (firing pressures, exhaust gas temperatures, charge air pressure, etc.) are to be checked and compared with the acceptance record. Standard running-in programme In the case of engines driving generators, the engine speed is, within the specified period, at first increased up to the normal speed before load is applied. During the entire running-in period, the engine output is to remain within the output range that has been marked in Figure 29, Page 2-14 and Figure 2-10, Page 2-14, resp. Critical speed ranges are to be avoided. Running-in during commissioning at site Four-stroke engines are, with a few exceptions, always subject to a test run in the manufacturer’s works, so that the engine has been run in, as a rule. Nevertheless, repeated running is required after assembly at the final place of installation if pistons or bearings were removed for inspection after the test run or if the engine was partly or completely disassembled for transportation.
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Running-in after installation of new running gear components In case cylinder liners, pistons and/or piston rings are replaced on the occasion of overhaul work, the engine has to be run in again. Run-
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ning-in is also required if the rings have been replaced on one piston only. Running-in is to be carried out according to Figure 2-9, Page 2-14 and Figure 2-10, Page 2-14, and/or the pertinent explanations. The cylinder liner requires rehoning according to MAN B&W Diesel Work Card 050.05 unless it is replaced. A portable honing device can be obtained from one of our service bases. Running-in after refitting used or installing new bearing shells (main bearing, big-end and piston pin bearings) If used bearing shells were refitted or new bearing shells installed, the respective bearings will have to be run in. The running-in period should be 3 to 5 hours, applying load in stages. The remarks in the previous paragraphs, especially under "Checks", as well as Figure 2-9, Page 2-14 and Figure 2-10, Page 2-14, resp., are to be observed. Idling at high speed over an extended period is to be avoided, wherever possible. Running-in after low-load operation Continuous operation in the low-load range may result in heavy internal contamination of the engine. Combustion residues from the fuel and lubricating oil may deposit on the top-land ring of the piston, in the ring grooves and possibly also in the inlet ducts. Besides, the charge air and exhaust piping, the charge air cooler, the turbocharger and the exhaust gas boiler may become oily. As also the piston rings will have adapted themselves to the cylinder liner according to the loads they have been subjected to, accelerating the engine too quickly will result in increased wear and possibly cause other types of engine damage (piston ring blow-by, piston seizure). After prolonged low-load operation (≥ 500 operation hours), the engine should therefore be run in again, starting from the output level, at which it has been operated, in accordance with Figure 2-9, Page 2-14 and Figure 2-10, Page 2-14.
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Data concerning all engines
Please also refer to the notes in Chapter 2.1.7 "Load application", Page 2-18. Note! For additional information, the after-sales service department of MAN B&W Diesel or of the license will be at your disposal.
Standard running-in program for engine 32/40 (constant speed)
A Engine speed nM B Engine output (specified range)
Figure 2-10
Standard running-in program for engine 48/60 (constant speed)
A Engine speed nM B Engine output (specified range)
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D Running-in period [h] E Engine speed and output [%]
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Figure 2-9
D Running-in period [h] E Engine speed and output [%]
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2.1.5
Acceleration times PDS: 230 110
Figure 2-11
Running-up and loading times, lube oil 20°C, engine cooling water 20°C
Minimum temperatures required Lube oil Engine cooling water
Running–up and loading times °C
20
-
Engine start and acceleration up to 100% engine speed Loading gradually up to 30% load Warming up engine: Lube oil up to 40°C Cooling water up to 60°C Loading gradually up to 70% load Warming up engine to operating temperature Loading gradually up to 100%
min
1-3
min min
5 5 - 10
min min
5 - 10 5 - 10
min
5 - 10
Time since engine start
min
26-48
Time since engine loading
min
25-45
-
-
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Data concerning all engines
Figure 2-12
Running–up and loading times, lube oil 40°C, engine cooling water 60°C
Minimum temperatures required Lube oil Engine cooling water
Running–up and loading times °C
40 60
-
Engine start and acceleration up to 100% engine speed Loading gradually up to 50% load Warming up engine to operating temperature Loading gradually up to 100% load
min
1-3
min min
5 - 10 5 - 10
min
5 - 10
Time since engine start
min
16 - 33
Time since engine loading
min
15 - 30
-
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Data concerning all engines
2.1.6
Standard reference conditions
Available outputs General definition of Diesel engine rating (according to ISO 15550: 2002; ISO 3046-1 : 2002)
ISO reference conditions
Air temperature Tr (tr)
No de-rating required in case of
≤ 308 K (35°C)
298 K (25°C)
Air pressure pr
100 kPa (1bar)
95,5 kPa (0,955 bar)
Cooling water temperature upstream of charge air cooler Tcr (tcr)
298 K (25°C)
≤ 315 K (42°C)
Realtive humidity Exhaust gas overpressure after turbine pEx
Available outputs/ related reference conditions
30%
≤ 50%
≤ 3 kPa
≤ 3 kPa
Nominal output according to Project Guide
Fuel stop power
Other conditions
%
%
-
Stationary power plnats 32/40, 48/60,
100
110
(1)
32/40, 48/60
100
110
(1)(2)(3)
Auxiliary engines for offshore application
100
110
(1)
Emergency generating sets
Notes:
0201-0502PA.fm
(1) Blocking of the output is made at 110% of the maximum continuous output. Output greater than the max. continuous output at site may only be run for a short time for the governing purposes. Please see also sheet “Power adjustment for ambient conditions at site for stationary power plants” on page 25.. (2) Consultation with MAN B&W Diesel AG is required (3) Permissible total running time according to DIN6280 1000h/a.
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Data concerning all engines
2.1.7
Load application PDS: 230 110
Load application from 0% to 100% rating (ISO 8528-5 requirements) For applications in the range from 0% to 100% of the site rating, the requirements according to Section 9 and Figure 6 of ISO 8528-5: 1993 apply. Please also refer the figure below.
Figure 2-13
Engine
Load application in steps as per ISO 8528-5
bmep
1st step
2nd step
3rd step
4th step
bar
%
%
%
%
33
23
18
26
32/40
21.9 ... 24.9
48/60
22.6 ... 23.2
Table 2-1
Depending on the mean effective pressure of the engines a load application from 0 to 100% results in the number of load steps an their percentages given in the table below.
Mean effective pressures and application loads according to ISO 8528-5
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The percentage of the load steps referring to a bmep of 24.8bar in the diagram.
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Data concerning all engines
Load application from any basic load (ISO 8528-5 requirements) Based on ISO 8528-5 requirements, the application rates shown in the following figure are required for load application from any basic load:
Figure 2-14
Load application depending on the current load according to ISO 8528-5
0201-0601PA.fm
Reference pressure bmep = 24.8bar
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Data concerning all engines
Load application allowed by MAN B&W Diesel As a standard MAN B&W Diesel allows higher load application than required by ISO 8528-5, see the figure below.
Load application depending on the current load allowed by MAN B&W Diesel AG
Requirements for plant design
Important
• Load application according to Table 2-1, Page 2-18, and Table 2-14, Page 2-19, must be taken into consideration for the plant design.
It is absolutely necessary that all questions regarding the dynamical behaviour of the engines are clarified prior to contract conclusion and for all customer requirements and MAN B&W Diesel AG confirmations are fixed in writing in the delivery contract.
• Running-up and loading times have to be in accordance with Chapter 2.1.4 "Engine Running-in", Page 2-12. • For the design of a plant with isolated electrical systems take Chapter 2.1.10 "Generator plants in isolated operation", Page 2-30, into consideration. Jet-Assist For power plants, jet-assist is necessary if load application > 25% of the engine output is required.
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Load reduction Sudden load throw-off The sudden load throw-off represents a rather exceptional situation and corresponds to opening the generator switch of a Diesel-electric plant. Care is to be taken that, after a sudden load throw-off, the system circuits remain in operation at least 5 min. to 10 min. in order to dissipate the residual engine heat.
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Figure 2-15
Data concerning all engines
Recommended load reduction / stopping the engine
high for all load conditions which, however is of particular importance during operation on heavy fuel oil.
• Unloading the engine In principle, there are no regulations with regard to unloading the engine. However, a minimum of 1 min. is recommended for unloading the engine from 100% PNominal to approx. 25% PNominal. • Engine stop As from 25% PNominal, further engine unloading is possible, without interruption, and afterwards the engine can be stopped. • Run-down cooling In order to dissipate the residual engine heat, the system circuits should be kept in operation for a minimum of 5 min. Part-load operation Definition Generally the following load conditions are differentiated: • Over-load (for regulation): >100% of full load output • Full-load:
100% of full load output
• Part-load: 3kPa) raises the temperature level of the engine and will be considered when calculating a required derating by reducing the ambient substitute temperature (Tra) by 2.5K for every 1kPa of the increased exhaust gas back pressure after the turbine. pEx ≤ 3kPa → tEx = 0 tEx> 3kPa → tEx = 2.5 × (pEx - 3)
For engines for electrical power generation, the specifications given in ISO 8528-1:1993. 13.3, apply.
p x 0.7 308 – t Ex 1.2 315 × ----------------------- × ------------------------ k = ----------- 95.5 273 + t 273 + t
α≤1
Note:
ISO 3046–1: 2002. Section 10.4: Types of power output
Px = Pr × α 0.7
Tra
Ambient total air pressure at site [kPa] Nominal output acc. to table of ratings [kW] Output at site [kW] Charge air coolant temperature at site [°C] Correction temperature for exhaust pressure [°C] Ambient air temperature at site [°C] Substitute reference for charge air coolant thermodynamic temperature = 315 [K] Substitute reference for ambient air thermodynamic temperature = 308 [K]
Output can be overloaded up to 10% for a short time for governing purposes (ISO 8528-1:1993).
Standard reference conditions
px k = -------- p ra
px Pr Px tcx tEx tx Tcra
ISO 8528–1: 1993. Section 13.3: Types of power output For all types of power output, it is necessary to provide additional engine power for governing purposes only (e.g. transient load conditions and suddenly applied load). This additional engine power is usually 10% of the rated power of the generating set and should not be used for the supply of electrical consumers. This additional power is not identical to the overload power for reciprocating internal combustion engines as defined in ISO 3046-1.
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Data concerning all engines
Illustration of continuous power
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Figure 2-18
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Data concerning all engines
2.1.9
Exhaust gas emissions PDS: 230 110
Composition of exhaust gas of medium speed four-stroke Diesel engines
combustion process. Only some of these are to be considered as harmful substances.
The exhaust gas of a medium speed four-stroke Diesel engine is composed of numerous of constituents. These are derived from either the combustion air and fuel oil and lube oil used, or they are reaction products, formed during the
The table below show the typical composition of the exhaust gas of an MAN B&W Diesel fourstroke Diesel engine at full load and without any exhaust gas treatment devices
Main exhaust gas constituents
approx. [% by volume]
approx. [g/kWh]
Nitrogen N2
74.0 - 76.0
5020 - 5160
Oxygen O2
11.6 - 12.6
900 - 980
Carbon dioxide CO2
5.2 - 5.8
560 - 620
Steam H2O
5.9 - 8.6
260 - 370
Inert gases Ar, Ne, He...
0.9
75
> 99.75
7000
approx. [% by volume]
approx. [g/kWh]
Total
Additional gaseous exhaust gas constituents considered as pollutants Sulphur oxides SOx
1)
0.08
12.0
2)
0.08 - 0.15
9.6 - 16.0
Carbon monoxide CO
3)
0.006 - 0.011
0.4 - 0.8
Hydrocarbons HC
4)
0.1 - 0.04
0.4 - 1.2
25%)
approx. 3 times
Guiding values for the number of Jet Assist manoeuvres dependent on application
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Table 2-5
Jet Assist activating time: Normally 3 sec to 10 sec. (5 sec. in average)
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Data concerning all engines
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Data concerning all engines
2.1.13
Condensate amount
Charge-air pipes, air vessels
Figure 2-20
Diagram condensate amount
The amount of condensation water precipitated from the air can be quite large, particularly in the tropics, and depends of the condition of the air drawn in, when the temperature of the charge air in the charge-air pipes drops below the dew point .
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The volume of condensate in the air vessels is determined by means of the curve at the bottom right of the diagram, representing an operating pressure of 30bar.
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Data concerning all engines
Determine the amount of water accumulating in the charge air pipe, Parameter
Unit
Value
Engine output (P)
kW
2,880
Specific air flow (le)
kg/kWh
7.1
Ambient air condition (I):
Ambient air temperature Relative air humidity
°C %
35 90
Charge-air condition (II):
Charge-air temperature after cooler Charge-air pressure (overpressure)
°C bar
50 2.6
Water content of air according to point of intersection (I)
kg of water / kg of air
0.033
Maximum water content of air according to point of intersection (II)
kg of water / kg of air
0.021
Solution acc. to above diagram:
The difference between (I) and (II) is the condensed water amount (A) A = I – II = 0.033 – 0.021 = 0.012 kg of water / kg of air Total amount of condensate QA: Q A = A × le × P Q A = 0.012 × 7.1 × 2880 = 245.4 kg/h
Determine the amount of water condensing in the compressed air vessel Parameter
Unit
Value
Volumetric capacity of tank (V)
litre m3
4,000 4
Temperature of air in vessel (T)
°C K
40 313
Overpressure in vessel (p) Absolute pressure in tank (pabs)
bar bar N -------
30 31 31 × 10
Gas constant for air (R)
Nm --------- × K kg
287
Ambient air temperature
°C
35
Relative air humidity
%
90
Water content of air according to point of intersection (I)
kg of water / kg of air
0.033
Maximum water content of air according to point of intersection (III)
kg of water / kg of air
0.002
m
2
5
Weight of air in the tank is calculated as follows: 5 p×V 31 × 10 × 4 m = ------------- = -------------------------------- = 138 kg 287 × 313 R×T Solution acc. to above diagram:
The difference between (I) and (III) is the condensed water amount (B) B = I – III B = 0.033 – 0.002 = 0.031 kg of water / kg of air
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0201-1003PA.fm
Total amount of condensate in the vessel QB: QB = m × B QB = 138 * 0.031 = 4.28 kg
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Engine 48/60
2.2
Engine 48/60
2.2.1
Outputs, speeds and designations PDS: 10
Engine V 48/60 Engine ratings Engine type No. of cylinders
500 rpm
514 rpm
Engine kW
Generator1) kW
Engine kW
Generator1) kW
12V 48/60
12
12,600
12,260
12,600
12,260
14V 48/60
14
14,700
14,305
14,700
14,305
18V 48/60
18
18,900
18,390
18,900
18,390
Table 2-6 1)
Engine rating
Engine ratings - engine V 48/60
Power factor 0.8
0203-0101PD.fm
Related data sheet see Chapter 2.1.6 "Standard reference conditions", Page 2-17.
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Engine 48/60
Engine 48/60 Speeds/main data Unit
50 Hz
60 Hz
kW (PS)
1,050 (1,430)
1,050 (1,430)
Rated speed
rpm
500
514
Mean piston speed
m/s
10.0
10.3
Mean effective pressure
bar
23.2
22.6
-
6
7
Cylinder rating
Number of pole pairs Highest engine operating speed Table 2-7
525
525
Speeds/main data - engine 48/60
This concession may possibly be restricted. See Chapter 2.1.8 "Adjustment of output and power", Page 2-23.
0203-0102PD.fm
1)
rpm
1)
Page 2 - 38
Version 08/2003
Engine 48/60
Engine V 48/60 Engine designation and design parameters Parameter
Unit
Number of cylinders
12, 14, 18 -
Vee engine Cylinder bore
Table 2-8
V 48
cm
Piston stroke
Abbreviations
60
Engine designations - engine V 48/60
Parameter
Unit
Cylinder bore
480 mm
Piston stroke
Value
600
Swept volume of each cylinder
litres
108.6
Compression ratio 1050 kW/cyl
-
15.3
Distance between cylinder centres
mm
1000
°
50
Vee angle Crankshaft diameter at journal Crankshaft diameter at crank pin
415
Design parameters - engine V 48/60
0203-0103PD.fm
Table 2-9
480 mm
Version 08/2003
Page 2 - 39
Engine 48/60
2.2.2
Dimensions, weights and cross sections PDS: 10
Engine V 48/60 Dimensions and weight
L = 9835mm
TCA77
14V48/60B
L = 10835mm
TCA77
18V48/60B
L = 12606mm
TCA88
181t 206t 256t
Main dimensions - engine V 48/60
0203-0201PD.fm
Figure 2-21
12V48/60B
Page 2 - 40
Version 08/2003
Engine 48/60
Engine V 48/60 Cross section
Cross section, view on counter coupling side - engine V 48/60
0203-0202PD.fm
Figure 2-22
Version 08/2003
Page 2 - 41
0203-0202PD.fm
Engine 48/60
Page 2 - 42
Version 08/2003
Engine 48/60
2.2.3
Calculation of performance (Projedat)
0203-0301PD.fm
The performance of the engine is calculated using the programme "Projedat" developed by MAN B&W Diesel.
Figure 2-23
Examples for engine 48/60 are given in the following.
Calculation of operating data - example for engine 48/60
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Page 2 - 43
Engine 48/60
Calculation of operating data - example for engine 48/60 0203-0301PD.fm
Figure 2-24
Page 2 - 44
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Engine 48/60
2.2.4
Engine noise PDS: 10
Engine V 48/60 Output 1050 kW/cyl., speed = 500/514 rpm Engine noise
Sound pressure level
Octave level diagram
Approx. ≤ 107.5dB(A) Approx. ≥ 102.5dB(A)
In the octave level diagram below the minimum and maximum octave levels of all measuring points have been linked by graphs.
Measuring points
Engines with lower ratings are between these curves.
A total of 18 measuring points at 1 m distance from the engine surface distributed evenly around the engine according DIN 45635 Part 11, Section 5.4.3.
Octave level diagram - engine V 48/60
0203-0501PD.fm
Figure 2-25
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Page 2 - 45
Engine 48/60
2.2.5
Intake noise PDS: 10
Engine V 48/60 Output.
0203-0601PD.fm
Intake noise
Page 2 - 46
Version 08/2003
Engine 48/60
2.2.6
Exhaust gas noise PDS: 10
Engine V 48/60 Output 1050 kW/cyl., speed = 500/514 rpm Exhaust gas noise
0203-0701PD.fm
The exhaust gas sound level at a distance of 1m from the exhaust gas pipe outlet opening (DIN 45635 Part 11, Appendix A), without a silencer, is approx. 120dB(A) ±3dB(A) at rated output.
Version 08/2003
Page 2 - 47
Engine 48/60
2.2.7
Planning data PDS: 210
Engine V 48/60 1050 kW/cyl.; 500/514 rpm Coolers Reference conditions: Fan cooling Air temperature
25
Cooling water temperature before charge air cooler (LT stage)
°C
32
Air pressure
bar
1
Relative humidity
%
30
Number of cylinders
-
12V
14V
18V
kW
12,600
14,700
18,900
Cylinder cooling water
1180
1375
1765
Charge air cooler HT-stage
3095
3530
4345
1135
1360
1945
1515
1770
2275
Cooling water fuel nozzles
28
33
42
Heat radiation engine
485
565
730
140
160
200
170
200
250
3.4
4.0
5.0
325
370
460
Engine output Heat to be dissipated
1)
Charge air cooler LT-stage Lube oil cooler + separator
2)
kW
Flow rates HT circuit (cylinder + charge air cooler HT-stage) LT circuit (lube oil cooler + charge air cooler LT-stage) Cooling water – fuel nozzles module
m3/h
Lube oil (5 bar before engine) 3) Temperature basis HT cooling water engine outlet LT cooling water air cooler inlet Lube oil engine inlet Table 2-10
90 °C
32 55
Coolers - engine V 48/60
1)
Tolerance: +10% for rating coolers, -15% for heat recovery Including separator heat (30kJ/kWh) 3) Without back washing oil required for filter, reserve for control valve and the tolerances of the pump delivery capacities. Table shows guide values only. Please contact MAN B&W Diesel to have exact values calculated.
Page 2 - 48
Version 07/2004
0203-0901PD.fm
2)
Engine 48/60
Engine V 48/60 1050 kW/cyl.; 500/514 rpm Air and exhaust gas data Reference conditions: Fan cooling Air temperature Cooling water temperature before charge air cooler (LT stage)
25 °C
32
Air pressure
bar
1
Relative humidity
%
30
Number of cylinders Engine output
-
12V
14V
18V
kW
12,600
14,700
18,900
°C
41
43
43
m3/h
73820
86130
110770
t/h
86.3
100.7
129.5
Air data Temperature of charge air at charge air cooler outlet Air flow rate
Charge air pressure (absolute)
bar
4.09
Exhaust gas data 1) m3/h
154970
180800
232460
Mass flow
t/h
88.8
103.6
133.2
Temperature at turbine outlet
°C
Heat content (210°C)
kW
Volume flow (temperature turbocharger outlet)
Permissible exhaust gas back pressure after turbocharger Table 2-11
mbar
335 3270
3810
4900
< 30
Air and exhaust gas data - engine V 48/60
1)
0203-0902PD.fm
Tolerances: quantity ±5%, temperature ±20°C Table shows guide values only. Please contact MAN B&W Diesel to have exact values calculated.
Version 5/2003
Page 2 - 49
Engine 48/60
Engine 48/60 Water and oil volume of engine, flow resistances, operating pressures Note: Exhaust gas back pressure
Water and oil volume of engine 12
14
18
1,250
1,400
1,700
325
380
490
No. of cylinder
litres
Lube oil approx. Table 2-12
Water and oil volume - engine V 48/60
Flow resistance
bar
Charge air cooler (HT stage)
0.35 per cooler
Charge air cooler (LT stage)
0.40 per cooler
Cylinder (HT cooling water)
1.0
Fuel nozzles (water)
1.5
Table 2-13
Flow resistances - engine 48/60 bar 1)
Operating pressures min.
max.
LT cooling water before charge air cooler stage 2
2.0
4.0
HT cooling before cylinders
3.0
4.0
Nozzle cooling water before fuel valves open system closed system
2.0 3.0
4.0 5.0
Fuel Oil before injection pumps
4.0
8.0
L = 4.0 V = 5.0
L = 5.0 V = 5.5
Lube oil before engine Exhaust gas back pressure After turbocharger Negative intake pressure before compressor
30mbar 20 mbar
Maximum cylinder pressure
190
Blow-off pressure (nozzle)
350
Table 2-14 1)
Operating pressures - engine 48/60 0203-0904PD.fm
Cooling water approx.
An increased exhaust gas back pressure (> 30mbar) raises the temperature level of the engine and will be considered when calculating a required derating by adding 2,5K to the ambient temperature for every 10mbar of the increased exhaust gas back pressure after the turbine.
All pressures overpressures
Page 2 - 50
Version 08/2003
Engine 48/60
2.2.8
Maintenance and spare parts PDS: 10 50
Engine 48/60 Maintenance
Component
Spot checks 5,000 - 6,000 h
Spot checks 10,000 - 12,000 h
Time between overhauls 15,000 - 20,000 h
Time between overhauls 30,000 - 40,000 h
Exhaust valve
x
x
Inspection / grinding
Inspection / replacement
Inlet valve
x
x
Inspection / grinding
Inspection / replacement
Piston
x
x
Inspection
Inspection / replacement
Piston ring
x
x
Replacement
Replacement
Connecting rod bearing
-
x
Inspection
Replacement
Cylinder liner
x
x
Inspection / honing
Inspection / honing / O-ring change
Main bearing
-
x
Inspection
Inspection / replacement
Table 2-15
Maintenance intervals
0203-1001PD.fm
The intervals are guidelines. Correct operation and maintenance must be ensured.
Version 08/2003
Page 2 - 51
Engine 48/60
Engine 48/60
0203-1002PD.fm
Spare parts
Page 2 - 52
Version 08/2003
Engine 48/60
Engine 48/60
0203-1002PD.fm
Spare parts
Version 08/2003
Page 2 - 53
Engine 48/60
Engine V 48/60
0203-1003PD.fm
Major spare parts
Page 2 - 54
Version 08/2003
Engine 48/60
2.2.9
Turbo charger
0203-1101PD.fm
PDS: 10 20
Figure 2-26
Turbocharger for engine 48/60
Figure 2-27
Explanation of acting forces and moments on the turbocharger exhaust- outlet
Version 08/2003
Page 2 - 55
Engine 48/60
Description and function
1 2 3 4 5 6 7 8 9 10 11 12 13
TCA 77 - engine 48/60
Silencer Insert Compressor casing Diffuser Bearing casing Bearing bush, compressor side Bearing body Turbine rotor Gas outlet casing Bearing bush, turbine side Nozzle ring Gas-admission casing Turbine blades
Page 2 - 56
14 15 16 17 18 19
Casing foot Gas-outlet diffuser Outlet, washing water Thrust bearing Compressor wheel Discharge, compressed fresh air
0203-1101PD.fm
Figure 2-28
Version 08/2003
Engine 48/60
Description Economical operation of modern large-scale engines is not imaginable without exhaust gas turbochargers. The already high requirements for propulsion systems and energy producing units concerning efficiency and longevity are being continuously increased under the aspects of fuel utilization and environmental load. In this, the components of exhaust gas turbochargers are subject to extreme operating conditions. • Exhaust gases of up to 650°C continuously flow through the turbine and heat up its components, without an own counteractive cooling system. Especially the shaft bearing must withstand the high operating temperatures without the lubricating film ever breaking. • On the compressor side, the air is heated to over 200°C. • The high temperatures lead to extreme thermal loads of the material at many locations. • Speeds are extremely high: The MAN B&W Diesel exhaust gas turbochargers are operated with speeds ranging from 10.000 to 35.000rpm, depending on size. In this, circumferential velocities of 560m/s and more are reached at the compressor wheel, which amounts to 1.7 times the speed of sound or 2.000km/h. • The centrifugal forces are extremely high: Forces of several hundred kN can easily apply at the foot of the turbine blade. • The complete gas exchange of the engine is performed by the exhaust • Gas turbocharger. For this machine, the throughput of combustion air can amount to 32.5m3/s.
0203-1101PD.fm
• Simplified, it can be said that approx. 1/3 of the power produced by the engine is converted on minute space within the exhaust gas turbocharger. These requirements can be fulfilled only with use of the most recent material and manufacturing technologies, introduced into the series by MAN B&W Diesel with use of the latest developmental
Version 08/2003
results, and based on decades of experience in building Diesel engines and exhaust gas turbochargers. Sub assemblies Turbochargers consist mainly of a turbine and a compressor, which are seated on the same shaft. The exhaust gas of the engine drives the turbine; the compressor draws in fresh air and compresses it. The turbocharger consists of the following main sub assemblies: • Rotating element: Turbine wheel and shaft are firmly connected together; the turbine blades are individually set into the turbine wheel. The compressor wheel is mounted on the shaft. • Bearing casing: The interior bearing of the running equipment consists of two bearing bushes and a thrust bearing. Lubrication of the bearing is carried out via the lube oil circuit of the engine. Lubricating oil pipes, lube oil venting and sealing air pipes are integrated in the bearing casing. • Gas-admission casing: The nozzle ring is built into the gas-admission casing. It enables optimum adaptation of the turbocharger to the engine. • Gas outlet casing: The gas-outlet diffuser in the outlet casing is flow-technically optimized. The outlet casing is fitted with 5 offset connections for the washing water outlet. Depending on the build-in position of the turbocharger, the connection positioned lowest is used. The outlet casing is designed so that together with the flanged-on gas admission casing, it offers optimum burst protection for the turbine wheel. • Silencer or air intake casing • Compressor casing optional with one or two discharge connections. The compressor casing houses the diffuser, which allows for op-
Page 2 - 57
Engine 48/60
timum adaptation of the turbocharger to the engine. Additionally, the diffuser functions as burst protection. Function The exhaust gas of the engine flows through the gas-admission casing and the nozzle ring, and runs axially onto the turbine wheel. The exhaust gas drives the turbine wheel; in this process, the energy contained in the exhaust gas is transformed into mechanical rotation energy at the turbine wheel. As the turbine wheel and the compressor wheel are seated on the same shaft, the compressor wheel is driven at the same time. The exhaust gas exits the turbocharger through the gas-outlet diffuser and the gas outlet casing. The compressor wheel draws in fresh air through the silencer or the intake casing and the insert. The fresh air is compressed in the compressor wheel, diffuser and compressor casing. The compressed fresh air is forced into the cylinders of the engine via charge air cooler and charge air pipe.
0203-1101PD.fm
The running equipment of the turbocharger is led radially by two bearing bushes, which are situated in the bearing casing between turbine wheel and compressor wheel. The thrust bearing positioned on the compressor side not only handles the axial guidance, but also transfers the thrust in axial direction. A bearing body holds the bearing seat and at the same time is used as insulation against the hot exhaust-gas side of the turbocharger.
Page 2 - 58
Version 08/2003
Engine 48/60
Lube oil system
Figure 2-29
Supply pipe Pressure reduction valve (4-stroke) Turbocharger supply pipe Non-return valve Pressure monitor Manometer Bearing casing Locating bearing Bearing bush
0203-1101PD.fm
1 2 3 4 5 6 7 8 9
Lube oil system for TCA 77 - engine 48/60
Version 08/2003
10 Drain pipe (α > max. inclination of system: + 5°) 11 Service tank or crankcase 12 Venting 13 Non-return valve with bypass 14 Bore 15 Supply/drain pipe 16 Orifice 17 Overflow pipe 18 Post lubrication tank
Page 2 - 59
Engine 48/60
Functional description Lube Oil Circuit: The lubrication and cooling of the high-stressed bearing bushes in the turbocharger takes place by means of a lube oil system, which is integrated mainly in the bearing casing. The lubricating oil is supplied from the lube oil system of the engine to the lube oil system of the turbocharger via a supply pipe (1). A pressure reduction valve (2.1) (four-stroke engine) adjusts the required lube oil pressure. The lube oil pressure is controlled behind the non-return valve (4) by means of a pressure monitor (5) and a manometer (6).
0203-1101PD.fm
The lubrication oil flows through the non-return valve (4) into the turbocharger casing, from where it reaches the thrust bearing (8) and the bearing bushes (9) via passages in the bearing casing (7) and the bearing body. The lubricating oil flows to the gap between bearing and shaft as well as to the face-sided lubrication point of the thrust bearing via bores in the bearing bushes. The lubricating oil leaves the gap between the bearing and the shaft and is splashed against the wall of the bearing casing by the rotation of the shaft. The lubricating oil exits the bearing casing through the drain pipe (10) and flows back into the lube oil system of the engine (11).
Page 2 - 60
Version 08/2003
Engine 48/60
Sealing air system
Figure 2-30 1 2 3 4 5 6 7
Sealing air system of TCA 77 - engine 48/60
Compressor casing Ring duct, compressor side Orifice Sealing air pipe Ring duct, turbine-side Compensation pipe Non-return valve
Functional description
0203-1101PD.fm
The sealing air prevents hot exhaust gas from entering the bearing casing and the lubricating oil from seeping into the turbine (oil coke). Additionally, undesirable axial thrust on the bearing bushes is reduced. The sealing air system is fully integrated in the bearing casing (11). A part of the air compressed by the compressor wheel (C) is diverted and
Version 08/2003
8 9 10 11 12 C T
Pipe bend Bearing bush Locating bearing Bearing casing Gas outlet casing Compressor wheel Turbine wheel
flows out of the compressor casing (1) into a ring duct (2) in the bearing casing. From there, the air is led into the sealing air pipe (4), whereby an orifice (3) reduces the pressure to the required sealing air pressure. The air is led to a ring duct (5) on the turbine side of the bearing casing. There, the sealing air emerges between shaft and turbine labyrinth.
Page 2 - 61
Engine 48/60
Acceleration system "Jet Assist" (auxiliary air drive)
1 2 3 4 5
Jet assist, TCA 77 - engine 48/60
Pressure reducing station or orifice Solenoid valve Non-return valve Ring duct Insert
Functional description The "Jet Assist" acceleration system is used when special requirements are made towards swift and possibly soot-free acceleration, and/or towards the load applications of the engine.
Page 2 - 62
6 7 A C *
Bore Compressor casing Starting-air cylinder (30bar) Compressor wheel standard specification turbocharger
The engine control actuates the solenoid valve (2). Compressed air of 30bar now flows from the starting-air cylinder through the pressure reducing station or orifice (1), where it is reduced to a maximum of 4bar. The compressed air reaches the compressor casing (7) via a non-return valve
Version 08/2003
0203-1101PD.fm
Figure 2-31
Engine 48/60
(3) at a maximum of 4bar, from where it is led to the insert (5) via the ring duct (4).
0203-1101PD.fm
The compressed air is blown onto the compressor wheel (C) through several inclined bores (7) in the insert. On the one hand this provides additional air to the compressor, while on the other hand the compressor wheel is accelerated, thus increasing the charge air pressure.
Version 08/2003
Page 2 - 63
Engine 48/60
Cleaning system of the turbine - dry cleaning
1 2 3 4 5 6
Turbine dry cleaning - engine 48/60
Compressed air pipe (5 ... 8bar) Screw plug Granulate container Pipes (25 x 2.0 mm) Connection flange Adapter
Functional description The dry cleaning of the turbine is performed during operation at normal load of the engine. The granulate container (3) is equipped with a filling opening, a compressed air pipe (1) and a pipe (4) leading to the gas-admission casing (7). The pipes for compressed air are fitted with stop cocks (A) and (B). The granulate container is filled with cleaning granulates and shut tight. The stop cock (A) in
Page 2 - 64
7 8 9 10 A B
Gas-admission casing Gas-outlet casing Turbine wheel Nozzle ring Stop cock (compressed air) Stop cock (exhaust gas)
the compressed-air supply pipe is opened and compressed air flows into the granulate container. Afterwards, the stop cock (B) in the pipe leading to the gas-admission casing is opened. The compressed air blows the granulates out of the granulate container into the gas-admission casing, from where the exhaust gas flow transports the granulates to the turbine wheel. The granulates bounce against the nozzle ring and turbine wheel, thus removing deposits and contamination. The exhaust gas flow carries the
Version 08/2003
0203-1101PD.fm
Figure 2-32
Engine 48/60
granulates and contamination particles out of the system. Operating conditions • The granulate container (3) must be fastened at a suitable location. It may not be not be positioned lower than 1 m below the connection flange (5). • The pipe (4) may not be longer than 6 m and must be supported against vibrations. Ensure unobstructed flow. • Maximum operating temperature of the stop cock (B) (exhaust gas): ≤ 150°C.
0203-1101PD.fm
• The connection flange (5) can be attached either at the adapter (6) of the exhaust gas pipe or directly at the gas-admission casing (7).
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Engine 48/60
Cleaning system of the turbine - wet cleaning
Figure 2-33
Washing water Pressure reducer Nozzles Gas-admission casing Nozzle ring
6 7 8 B E
Turbine wheel Drain, washing water Drain funnel Drain valve Shut off valve water supply
0203-1101PD.fm
1 2 3 4 5
Turbine wet cleaning - engine 48/60
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Engine 48/60
Functional description The wet cleaning is performed during operation with heavily reduced engine load (approx. 10% for driven engines), in order to avoid overload of the turbine blades (thermoshock).
Cleaning system of the turbine - wet cleaning system of the compressor
The advantages of wet cleaning in comparison to dry cleaning are: • The better cleaning effect and thus longer cleaning intervals, • Control of the cleaning effect via the contamination degree of the drained washing water. The washing water flows through the stop cock (E). The washing lances spray the washing water in the exhaust gas pipe in front of the turbine. The washing water droplets bounce against the nozzle ring and the turbine, where they wear off the contamination. The washing water collects in the turbine casing and runs off through the washing water drain (7) and the drain valve (B). The washing water is led via a funnel (8) to a sediment tank, where it is collected. The funnel enables visual control of the washing water. The cleaning process is finished when the washing water remains clean.
Figure 2-34
1 2 3 4 5 6 7 8 9
Wet cleaning system, compressor - engine 48/60
Charge air pipe Pipe Key-button valve Hose Water tank with screwed connection Hose Injection pipe Compressor casing Charge air cooler
Functional Description The wet cleaning of the compressor is performed during operation at full load.
0203-1101PD.fm
The water tank (5) is filled with fresh water and tightly closed with the screwed connection. If the key-button valve (3) is opened, compressed air flows from the charge air pipe (1) into the water tank and presses the water out of the tank through the hose (6) to the injection pipe (7). The injection pipe sprays the water in the compressor casing (8) in front of the compressor wheel. The water droplets bounce against the compressor wheel, where they wear off the contamination.
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0203-1101PD.fm
Engine 48/60
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Version 08/2003
Quality requirements
Kapiteltitel 3.fm
3
Version 5/2003
Page 3 - 1
Kapiteltitel 3.fm
Page 3 - 2
Version 5/2003
Quality requirements 3.1 Quality of lube oil for operation on gas oil and Diesel oil (MGO/MDO)
3.1
Quality of lube oil for operation on gas oil and Diesel oil (MGO/MDO) PDS: 10, 30, 40, 90
as specified in Table 3-1, Page 3-3, particularly as concerns its aging stability.
The specific power output offered by today’s Diesel engines and the use of fuels which more and more often approach the limit in quality increase the requirements placed on the lube oil and make it imperative that the lube oil is chosen carefully. Doped lube oils (HD oils) have proven to be suitable for lubricating the running gear, the cylinder, the turbocharger and for the cooling of the pistons. Doped lube oils contain additives which, amongst other things, provide them with sludge carrying, cleaning and neutralization capabilities.
Doped lube oils (HD-oils) The base oil with which additives have been mixed (doped lube oil) must demonstrate the following characteristics: Additives The additives must be dissolved in the oil and must be of such a composition that an absolute minimum of ash remains as residue after combustion. The ash must be soft. If this prerequisite is not complied with, increased deposits are to be expected in the combustion chamber, especially at the outlet valves and in the inlet housing of the turbochargers. Hard additive ash promotes pitting on the valves seats, as well as burnt-out valves and increased mechanical wear.
Only lube oils, which have been released by MAN B&W Diesel, are to be used. These are listed in Table 3-3, Page 3-5. Specifications Base oil The base oil (doped lube oil = basic oil + additives) must be a narrow distillation cut and must be refined in accordance with modern procedures. Bright stocks, if contained, must neither adversely affect the thermal nor the oxidation stability. The base oil must meet the limit values Characteristic features Structure Behaviour in cold, still flows
Unit
Test method
Limit value
-
-
preferably paraffin-basic
ASTM–D2500
-15
°C
ASTM–D92
> 200
ASTM–D482
< 0.02
ASTM–D189
< 0.50
-
MAN B&W Diesel aging cabinet
-
n–heptane insolubles
Weight %
ASTM–D4055 or DIN 51592
t < 0.2
Evaporation loss
Weight %
-
