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Annexure - 1

Project layout plan

Annexure 2(a)
HFO Engine Specification

MAN Diesel & Turbo

Nababganj Power Plant - 55MW


Bangladesh

Technical Specification
3 MAN Gensets 18V48/60TS plus mechanical & electrical auxiliaries

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page i

MAN Diesel & Turbo

Revision History
Revision

Description

Date

Author

5301959-01-B001

Technical Specification 3x18V48/60TS

2012-02-21

Nikhil Ghag

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page ii

MAN Diesel & Turbo

Table of Contents
1

Design data and performance guarantees

1.1
1.2

Design data
Performance data

1
4

Diesel engine

2.1
2.2
2.3

Engine scope and special engine accessories


Engine System
Detailed Technical Specification of one engine 48/60TS

6
6
8

Generating set

10

3.1
3.2

Connecting elements
Genset

11
12

Mechanical scope

4.1
4.2
4.3

Auxiliary systems, engine related


Auxiliary systems, plant related
Exhaust gas system

Electrical scope

5.1

Control and monitoring system

Miscellaneous

6.1
6.2

Plant service and protection systems


Documentation

Tools, spare and wear parts

7.1

Tools and spares

Services

8.1
8.2
8.3
8.4
8.5

Quality Management, Quality Assurance


Project engineering
Logistics
Site activities
Project services

34
35
37
37
40

Requirements and limitations

43

9.1
9.2

Quality requirements for operating media


Limits of supply

43
46

10

Operation and maintenance

10.1

MAN Diesel & Turbo Service Worldwide

11

Standards, Guidelines and Drawings

11.1
11.2
11.3
11.4

Applicable standards
General guidelines
Drawings
Division of Works

12

General information

12.1
12.2
12.3

List of sub suppliers


References
Leaflets and brochures

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

15
15
18
21

22
22

30
30
30

31
31

34

48
48

49
49
49
50
50

51
51
52
57

Date 2012-02-21
Page iii

Nababganj Power Plant - 55MW


Section 1 - Design data and performance guarantees

1.1
1.1.1
Site conditions

1.1.2
Generating sets

Electrical
system

Design data and performance guarantees


Our quotation is based on following design data as well as the:
- Drawing of generating set: 11745001770_01_A_Genset Drawing
18V4860TS
Design data
Site conditions
All offered equipment is designed to operate within the following ambient
conditions:
Altitude above sea level
Wet bulb temperature
Minimum ambient air temperature
Maximum ambient air temperature
Operation outside of these limits without guarantee.

23 m
29 C
10 C
40 C

Generating sets
Under consideration of your request, this quotation provides for 3 generating
sets based on the MAN 18V48/60TS engine.
Number of generating sets
3
Engine type
18V48/60TS
-1
Engine speed
500 min
Lube oil pump
engine driven
HT cooling water pump
engine driven
LT cooling water pump
engine driven
The offered equipment is based on the following electrical values:
Operation mode
GRID ONLY
Frequency
50 Hz
Power factor cos phi (lagging)
0.8
Medium voltage
11 kV
Low voltage
400 V

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 1 of 58

Nababganj Power Plant - 55MW


Section 1 - Design data and performance guarantees

1.1.3
Foundation

Lube oil

Cooling method
Heavy fuel oil

Intake air
Power house
ventilation

Other design data


2
Soil bearing capacity
200 kN/m
Earthquake design according to Peak Ground Acceleration
1
PGA
0.2 g
Engine lube oil has to be in accordance to the requirements as stated in
section 9.1
Requirements for viscosity:
Viscosity-class (40)
SAE40
Features of the cooling water system:
Type of cooling system
RADIATOR
The fuel oil system is designed based on heavy fuel oil in accordance to the
requirements as stated in section 9.1.5.
Alternatively the engines can be operated on diesel fuel oil in accordance to
the requirements as stated in section 9.1.4 for up to 72 hours at a time.
Ambient air
free of dust, salt and sand
Design temperature rise
inside power house
17 K
The temperature rise to be measured between ventilation outlet und inlet.
The power house ventilation air is blown directly onto the alternator.
The alternator design temperature is 43 C.

Peak ground acceleration with a probability of 10% to be exceeded in 50 years and


a return period of 475 years based on reference ground with a shear wave velocity >
800 m/s

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 2 of 58

Nababganj Power Plant - 55MW


Section 1 - Design data and performance guarantees

Permissible
frequency limits

105

Continuous power

Load [%]

100

95

90
-6

-4

-2

Engine speed / Nominal speed [%]

Load
application

Table 1: Diagram of permissible frequency and load limits


Table 1 shows that the maximum continuous engine output is ensured at a
mains grid frequency exceeding up to max. +3%, whereas at a frequency drop
to max. -5%, the power output is continuously reduced to 95% MCR. We
permit operation of the engines up to +5% frequency fluctuation for maximum
120 seconds. In any case, the maximum permissible mains grid frequency
deviation is 5%.
When load is suddenly applied to a generating set there will be a transient
deviation in voltage and frequency. The maximum permissible load increase is
limited to steps of 25% of the nominal power of all generating sets in operation.
Further it depends on the base load before load increase.
The offered generating sets comply with ISO 8528-5 class G2.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 1 - Design data and performance guarantees

1.2

Site Reference
conditions

Measuring
tolerances

Performance data
The values given here are for information only and without guarantee.
Our stated performance data is based on the design data as per section 1.1
and calculated for the following reference conditions:
Air Inlet temperature (before air inlet filter)
35 C
Air Inlet pressure (before air inlet filter)
1011 mbar
Charge air temperature before cylinder
54 C
Exhaust gas back pressure
30 mbar
Intake air pressure loss
20 mbar
In case the site conditions / technical parameters at performance test are
different from the site reference conditions defined above, the performance
guarantees will be adapted in accordance to MAN standard procedure.
Tolerances in the measuring equipment shall be considered additionally and
are not included in the guarantee figures stated below. Tests will be done
according to ISO 15550:2002 (ISO 3046-3:1989).

1.2.1

Continuous power of the generating set


Data will follow

1.2.2

Specific fuel oil consumption (SFOC)


Data will follow

1.2.3

Lubricating oil consumption


Data will follow

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 2 - Diesel engine

2
General
description

Technical data

Continuous
development

Diesel engine
The MAN engine 18V48/60TS is a
four stroke, medium speed Diesel
engine, two-stage turbocharged and
charge air cooled. The engine is prepared for operation on HEAVY FUEL.
Compared to other medium speed
engines, covering the same power
range, the 18V48/60TS produces high
power from a compact, efficient design.
The technical data is summarised in the following table:
Cylinder bore
Piston stroke
Engine speed
Piston speed
Mean effective pressure
Power per cylinder
Power of the engine (at crankshaft)

480 mm
600 mm
-1
500 min
10.00 m/s
23.21 bar
1050 kW/cyl
18900 kW m

The engine familiy has a well proven service record in marine propulsion,
marine auxiliary genset and stationary power generation. 48/60TS engines
from MAN have been in service since 1989 and are subject to continuous
development to ensure reliability under the most severe service conditions.
Each 18V48/60TS engine is engineered to optimise its performance to ensure
that your individual requirements are met.

Outline
dimensions

Dimensions and weight of the engine 48/60TS:


Height (H)
Length (L)
Width (B)
Weight (dry)

5355 mm
13148 mm
4700 mm
255000 kg

The dimensions and weight stated correspond to the engine only. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guidance only and are subject to change without notice.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 5 of 58

Nababganj Power Plant - 55MW


Section 2 - Diesel engine

2.1
Item

010

Qty Description

2.2

Engine System

2.2.1

Engine System

MJA10 AV010

2.2.2
010.202

2.2.3
010.220.010

MJV21 AP050

2.2.4
010.230.010

Turbocharger off engine

Lubrication system
Engine attached lube oil pump(s)
Capacity approx. 504 m/h including pressure control valve and connecting
pipe between pumps

Cooling water system

Engine attached LT cooling water pump


nominal capacity 280 m/h. The cooling water flow through the charge air
cooler will be adapted to 280 m/h by installation of orifices.

2.2.5
3

2.2.6
010.290.420

Turbocharger off engine

Engine attached HT cooling water pump


Capacity approx. 220 m/h

MJG32 AP030

010.250.030

Engines 18V48/60TS, suitable for operation on heavy fuel oil, as per following
detailed Technical Specification

MJG31 AP030

010.230.020

Engine scope and special engine accessories

Special equipment of the engine


Slow-turn facility on the engine.
The engine is automatically turned slowly prior to engine start with being
monitored by the engine control. If the engine does not reach the expected
number of crankshaft revolutions within the specified period of time, an error
message is issued. Slow-turn serves as an indication that there is liquid (oil,
water, fuel) in the combustion chamber.

Engine control and monitoring


Sensors / cabling for TC off engine

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 6 of 58

Nababganj Power Plant - 55MW


Section 2 - Diesel engine

Item

Qty Description

2.2.7
010.330.020

Factory Acceptance Test (FAT)


Factory Acceptance Test of the engine
The test will be done with the MAN Diesel & Turbo testbed equipment and
installations but without other offered equipment.
Pre tests:
Checking of systems and installations
Testing of monitoring and safety equipment
Running-in and adjusting
Running up to 100% load
Adjusting of ignition pressure
Adjusting of governor
Checking of all operation data
Workshop test procedure:
Starting tests
approx. 15 min.
Warming up to 100% load
approx. 25 min.
Continuous power of 100% load
60 min.
Continuous power of 85% load
30 min.
Governor test
approx. 15 min.
For the FAT Diesel fuel and lube oil will be used in line with the MAN Diesel &
Turbo standards. The test will be executed according to the actual conditions
prevailing at our workshop. The operating values to be expected at site can be
calculated by using well-proven methods on basis of the main operating values
as certained on the test bed. The measuring parameters, including relevant
accuracies, are based on ISO 3046.
Extension or changes of our test programme would result in additional cost and
have to be clarified upon request.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 7 of 58

Nababganj Power Plant - 55MW


Section 2 - Diesel engine

2.3

Detailed Technical Specification of one engine 48/60TS

Design features

One-part crankcase with safety valves on crankcase covers


Crankshaft made of forged steel with torsional vibration damper at free end
Main bearings and big-end bearings with two-part thin-walled bearing shells
and main bearings cross-braced by tie-rods
Connecting rod (splitted with flange) drop-forged of steel
Three-ring piston with forged steel crown and nodular cast-iron skirt
Cast-iron cylinder liners with fire band ring
Nodular cast-iron cylinder head with armour-plated inlet and exhaust valves,
valve seat rings for the inlet and exhaust valves. Valve rotators on the inlet and
exhaust valves. Indicator valve on each cylinder
Multi-part camshaft for enhanced Miller timing
Pipes on the engine with counter flanges or connecting screws

Fuel injection
system

Injection pump on each cylinder


Rocking levers between camshaft and pump plungers, on an excentric shaft,
adjustable from outside for optimising the injection timing
Variable injection timing (VIT), with automatic adjustment
Injection pipes, double walled
2 buffer pistons at the fuel admission and return pipes

Speed control

Woodward EM300 electronic speed governor with actuator


Electric speed transmitter for engine speed and turbocharger speed
Electro-pneumatic emergency shutdown device on the engine for manual
remote emergency stop and for automatic stop at over speed and other stop
criteria within the safety system

Turbo charging
and charge-air
cooling

2 exhaust gas turbocharger, type TCA88 and TCA77 mounted at the FREE
END. Lube oil run down tank, decoupled from turbocharger. Washing device
(wet) for the exhaust gas turbine and compressor.
2 Charge-air cooler in fresh water and two-stage design; with counter flanges,
standard design for top removalAir pipe sound insulated between compressor
and charge air cooler (including air intake casing)
Exhaust gas piping on the engine, uncooled, thermally insulated and lagged

Platform

Brackets on the engine for attaching the main gallery supports

Operation and
control

Engine safety and control system SaCoS_one


comprising of:
Control unit, resiliently mounted on engine, consisting of high integrated control
modules, one for safety system and one for alarm handling and control,
including the following functions:
Splash oil temperature monitoring
Main bearing temperature monitoring
Lube oil temperature and pressure monitoring
Cooling water temperature and pressure monitoring
Charge air temperature and pressure monitoring
Exhaust gas temperature monitoring
Speed monitoring and overspeed protection
Engine control

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 8 of 58

Nababganj Power Plant - 55MW


Section 2 - Diesel engine

Electronic speed governing


Interface cabinet, as floor-standing cabinet for engine room installation
(standard colour RAL7035), including gateway module for plant communication
via interfaces to
Plant automation system
Power supply
Power management and starters for cylinder lubrication
Power management and starters for valve seat lubrication
HT, LT and CHATCO temperature control
Oil mist detector, make Schaller VN115
Temperature
measuring

Thermocouples for measuring the exhaust gas temperature after each cylinder,
before and after turbocharger, with terminal box and cabling on the engine.

Start and stop


equipment

Compressed air starting equipment with main starting valve and with starting
valve on each cylinder of one cylinder bank

Lubricating and
cooling

Cylinder lubrication oil pump with attached electrical motor (IP 55)
Forced-feed lubrication for all bearing points of running gear, camshaft, timing
gear, governor drive and turbocharger
Pressure control valve for engine lube oil
Cylinders, cylinder heads, fuel injection valves, and charge-air cooler are
water-cooled, pistons are oil cooled

Flywheel and
turning gear

Flywheel with toothing, without protection cover


Bolts connecting the flywheel with the crankshaft
Turning gear for the running gear, with electric motor (reversible; IP 54)
Push button switching equipment, control cable
Starting interlock when turning gear engaged, with limit switch (not cabled; 24
V DC; IP 65) for display

Engine painting

The outer surface of the engine is covered with paint white aluminium RAL
9006. Painting consists of one finishing coat, approx. 20 m.

Acceptance

Works acceptance / factory approval.

Calculation

Torsional vibration calculation

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 3 - Generating set

3
General
description

Generating set
Our generating sets are designed for power generation in continuous, durable
and safe operation. The area of application comprises ranges from supplies of
basic loads in public mains or coverage of peak loads to isolated applications
for industrial consumers.
The engine is rigidly mounted on a steel frame, acting as the lubricating oil
service tank, which is resiliently seated on a simple concrete foundation by
spring isolators. The alternator is connected to the engine by a flexible
coupling, rigidly mounted and grouted onto a separate and elevated concrete
foundation.
This genset design is prerequisite for our simple, small, single-floor power
house concept to get short assembly and commissioning periods at low cost.

Outline
dimensions

Dimensions and weight of the generating set:


Height (H)
Length (C)
Width (W)
Weight (dry)

6530 mm
18558 mm
4700 mm
375000 kg

The dimensions and weight stated correspond to the complete unit including alternator. The total weight varies depending on the alternator make. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guidance only and are subject to change without notice. The length of the genset unit
depends on the alternator make.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 3 - Generating set

Qty Description

Item

3.1

3.1.1

Connecting elements

Coupling arrangement

020.010.010

Flexible coupling
The flexible coupling is mounted between engine flywheel and alternator shaft.
The scope includes a connection hub for the alternator shaft and fixing bolts for
connection to the flywheel.
A standard coupling is used. Size and rubber quality are determined by the
torsional vibration calculation.

020.010.040

Cover for flywheel and coupling

3.1.2
020.020.020

3.1.3

Engine seating
Engine seating
Set of foundation bolts for ridgid seating of the engine.

Pipe adapters

020.030.025

Flexible pipe connections for the engine

020.030.080

Rubber expansion joint for intake air duct


to be installed upstream of turbocharger, delivered with counterflange

020.030.090

Adapter for exhaust gas duct


to be installed downstream of turbocharger, without counter flange

3.1.4

Low pressure turbo charger ducts

020.035.010 -1

Intake air ducting


interconnecting ducts for intake air between low pressure- and high pressure
turbo charger

020.035.020 -1

Exhaust gas ducting


interconnecting ducts for exhaust gas between low pressure- and high
pressure turbo charger

020.035.030 -1

Miscelleanous piping
consisting of lube oil, cooling water and starting air piping for the turbo charger
unit off engine, including steel structure for T/C support

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Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 3 - Generating set

Qty Description

Item

3.2

3.2.1
025.020.010 -1
MJA10 AG011

Genset

Alternator system
Three phase synchronous alternator
Design:
The stator frame is a rigid, welded steel structure construction. The stator core
is built of thin electric sheet steel laminations which are insulated on both sides
with heat-resistant inorganic resin. The radial cooling ducts in the stator core
insure uniform and effective cooling of the stator.
The rotor consists of a forged steel shaft, a hub and sheet steel poles fixed on
the hub. The pole laminations are pressed together with steel bars fixed to the
end plates.
The windings, epoxy resin impregnated, are provided with very strong bracing
which withstands all expected mechanical and electrical shocks and vibrations.
Engine-independent, self lubricated bearing design, to avoid possible lube oil
contamination by the engine.
The alternator is self-ventilated and needs no external forced air flow. The
surrounding air is used for cooling. The cooling air is drawn in through air filters
and blown out to the surrounding environment.
Rated technical data:
Output approx.
22988 kVA
Voltage
11 kV
Current approx.
1207 A
Frequency
50 Hz
Power factor
0,8
Temperature rise stator/rotor
F/F
Insulation class
F
Mounting design
IM1101 or IM7301
Protection class alternator
IP23
Protection class terminal box
IP54
Cooling method
IC0A1 (Air cooled)
Operation
S1, continuous
Operation mode
Grid parallel
Applicable standard
IEC 60034
The alternator is optimized for voltage-stability in case of load variation.
Accessories:
Anti-condensation heater
Pt100 sensors for winding temperature detection
Pt100 element and lubrication oil sight-glass for monitoring, for each
bearing
Main terminal box (terminals U/V/W/N) and auxiliary terminal box (for
accessories) inclusive suitable cable glands for bottom entry
Brushless self-excitation system including rotating diodes and protection

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 3 - Generating set

Item

Qty Description
against overvoltage
Droop current transformer installed in main terminal box
Star point current transformers for protection purposes installed in main
terminal box
Painting similar to engine colour
Foundation bolts
Final series test report according to manufacturers standard is included.

025.020.050

3.2.2

Automatic voltage regulator (AVR)


Digital excitation control system type Basler DECS 200 is installed on a
mounting plate integrated in the Genset Interface Panel (GIP).
Features:
Voltage regulation within 0.25% from no-load to full-load
Proportional (P), integral (I) and derivative (D) stability control
Underfrequency limiter or V/Hz ratio limiter
Paralleling compensation of two or more generators using reactive droop
Manual and automatic channel
Several protection functions
Diode monitoring function is included
Serial bus coupling for read out of different measuring values

Foundation system

025.030.010

Steel foundation frame


The engine is rigidly mounted and bolted on a steel foundation frame which is
resiliently seated on the foundation. The steel foundation frame is used as lube
oil service tank.

025.030.030

Grouting material for seating of alternator

025.030.050

Foundation frame seating


Spring elements for resilient, vibration-isolated mounting of the steel foundation
frame with engine on the concrete foundation including equipment for lining
(balancing aids) and fixing.

3.2.3

Genset addons

025.035.010

Frame auxiliaries and frame assembly


Engine and steel foundation frame are mounted at the MAN Diesel & Turbo
workshop. Attachment of turning gear, terminal boxes, piping and cabling is
included. Additionally an installation drawing is provided.

025.035.060

Lube oil tank level monitoring

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Nababganj Power Plant - 55MW


Section 3 - Generating set

Item

Qty Description

3.2.4

Genset service platforms

025.040.010

Engine service platform


Free standing engine service platform, with floor plates, railing, stair and
fasteners.

025.040.020

Interconnecting bridges for engine service platforms, with railing

025.040.050

Service platform for turbocharger

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Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Qty Description

Item

4.1

4.1.1
030.020.010 -1

Lube oil replenishing and flow rate measuring device consisting of:
Oval gear meter including pulse trigger
Solenoid valve

Lube oil separator module


consisting of:
Separator, self-cleaning, capacity min. 4725 l/h with motor
Switch cabinet, complete with control and power part as well as temperature
control and temperature switch
Steam heated lube oil preheater with safety valve and insulation
Sludge collector and sludge pump
Supply pump, not fitted

Oil mist eliminator


The vent gases originate from the following:
Crankcase: Gases from the combustion chamber leak past the piston rings
Turbocharger vent: The bearing housing of the turbocharger is pressurized
to prevent the hot exhaust gases entering the bearing housing. It is
pressurized by letting some of the gases from the compressor side of the
turbocharger into bearing housing. This process can not be controlled
precisely so some of the gases are vented via a pressure regulating value
to the atmosphere.
The oil mist eliminator reduces the air emissions from the vents of the engine
crankcase chamber and the turbocharger.

GBK37 AT020

030.020.280
MJV28 AN010

Lube oil service system


Lube oil module
consisting of:
Lube oil heat exchanger
Lube oil automatic filter
Lube oil priming pump with e-motor
lube oil temperature regulating valve
Terminal box
The above equipment is mounted on a frame with corresponding fittings
completely piped and wired.

MJV23 CF010

030.020.160

Auxiliary systems, engine related

MJG32 AP040

030.020.150

Mechanical scope

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Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Qty Description

Item

4.1.2
030.030.035

HT cooling water service system

Cooling-down pump, free-standing


capacity 30 m/h, with e-motor 2.5 kW

HT cooling water temperature regulating valve


with electric actuator, to be fitted in the cooling water pipe to radiator and
resistance thermometer Pt 100 to be fitted in HT cooling water pipe
downstream the mixing point.

030.030.050

Resistance thermometer for HT cooling water, loose supply

030.030.060

Cooling water expansion tank


The tank is designed with two separate compartments for HT and LT circuit,
capacity 1000/500 l, with mechanical level indicator and minimum alarm
contact

MJG31 AP020

030.030.040
MJG31 AA010

MJG31 BB010

4.1.3
030.040.050

LT cooling water temperature control valve


DN200, with electric actuator and resistance thermometer Pt100 to be installed
in LT cooling water pipe downstream the mixing point

Charge air temperature control valve (CHATCO)

Resistance thermometer for charge air temperature

MJG32 AA025

030.040.063

Low temperature cooling water system

MJG32 AA010

030.040.066
MJG32 AA015

4.1.4
030.050.010 -1
MJG31 AC020

Two circuit radiator cooling system


Two-circuit radiator cooling system
The engines are cooled with outside mounted, horizontal type radiators with
electrically driven induced draft fans with space heaters.
Scope of supply:
Radiator cooler with separate cooling circuits for high and low temperature
cooling water
Frame material: Hot dipped galvanized steel.
Tube material: copper
Fin material: Aluminum
The radiator coolers are designed for a minimum temperature of 10C (without
glycol) and a maximum ambient temperature of 40 C.
Supply without steel supporting structure.
Each engine is cooled by separate radiator units.
Noise power level of the radiators for one engine is 107 dB(A).

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Item

Qty Description

4.1.5
030.110.140

4.1.6
030.120.010

Fuel oil booster module


designed as single-module, acting engine related, consisting of:
Flow rate measuring device, volumetric type
Mixing tank
Booster pump with motor and safety valve
Stand-by booster pump with motor end safety valve
Fuel oil cooler for Diesel fuel oil
Duplex filter approx. 0.034 mm serving as indicator filter, with manual
change-over and differential pressure contact indicator
Pressure compensation tank
Control cabinet
The above equipment mounted on a frame, complete with pipes, with leakage
oil pan, fittings, valves, insulation and fixing bolts.

Combustion air system

Intake air filter unit


consisting of:
Vertical weather louvre
Pocket filters (dry filters)
Filter house
Difference pressure transmitter
Transition piece with integrated silencer for a noise attenuation of approx.
40 dB(A) and flange(s) to intake air duct

Intake air duct upstream of turbocharger


including supports

MJQ61 AC020

030.120.050

Fuel oil service system

4.1.7

Engine exhaust gas system

030.130.020

Expansion joint for exhaust gas duct


to be installed after adapter, without counter flange

030.130.030

Exhaust gas duct inside power house


with bend and supports, without wall sockets, without counterflange

4.1.8
030.160.010

Insulation
Insulation material for exhaust gas duct inside powerhouse
for heat insulation of the exhaust gas adapter, compensator and duct inside
power house, with jacketing, supplied loose.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 17 of 58

Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Qty Description

Item

4.2

4.2.1
040.010.020

Leakage oil module,


This module collects the fuel oil leakage quantities of the engine and of the fuel
oil module.
The leakage oil module is equipped with:
Leakage oil tank, 500 l capacity, with level indicator and level switch
2 Discharge pumps for fuel oil
Terminal box
The above equipment is mounted on a frame completely piped and wired.

Lube oil supply pump


capacity 3 m/h, with e-motor 2 kW. The pump is used to supply lube oil from
the storage tank to the service tank.

Lube oil transfer pump


capacity 10 m/h, with motor 4 kW and attached pressure relief valve. The
transfer pump is used to refill the foundation frame (lube oil service tank) with
the lube oil stored in the maintenance tank.

MJV23 AA010

040.010.040
MJV23 AP060

4.2.2
040.030.010 -1

MJG31 AC010

4.2.3
040.040.010

GBK35 AP010

HT cooling water supply system


Preheater set for cooling water
If, after a longer engine shut down, the temperature of the cooling water is
below 20C, preheating is necessary before the start-up of the engine.
A preheater set delivers the necessary energy. A circulating pipe interconnects
the preheating set with the engine.
Cooling water preheating module, consisting of:
Continuous flow water heater (steam heated)
Temperature regulator
Terminal box

Main water supply and condensate system

Cooling water collecting tank


capacity 10000 l with mechanical level indicating.

Cooling water replenishing pump


capacity 3 m/h, with e-motor 2 kW and expansion pot, capacity 200 l.

GBK35 BB050

040.040.020

Lube oil supply system

EGD51 AP040

040.010.030

Auxiliary systems, plant related

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 18 of 58

Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Item

Qty Description

4.2.4
040.045.010

MJG32 AP020

4.2.5
040.050.070

Heavy fuel oil pressure limiting valve for installation in piping for heavy fuel oil
inside the engine room.

4.2.6

Fuel oil treatment and supply unit

Heavy fuel oil separator module


consisting of:
Separator (self-cleaning), effective separator capacity min. 13422 l/h, with
motor
Switch cubicle complete with control and power part, as well as temperature
control and temperature switch
Steam heated fuel oil pre-heater with safety valve and lagging
Sludge collector and sludge pump
Flexible pipe connections
Supply pump, not fitted, with dirt trap.

Heavy fuel oil separator module (stand-by)


consisting of:
Separator (self-cleaning), effective separator capacity min. 13422 l/h, with
motor
Switch cubicle complete with control and power part, as well as temperature
control and temperature switch
Steam heated fuel oil pre-heater with safety valve and lagging- Sludge
collector and sludge pump
Flexible pipe connections
Supply pump, not fitted, with dirt trap.

EPN54 AC201

040.060.015

Fuel system, plant related


Diesel oil pressure limiting valve
to be mounted in the Diesel oil piping inside engine room.

END55 AA040

040.060.010

Nozzle cooling water module


consisting of:
Nozzle cooling water circulation pump with motor
Expansion tank
Heat exchanger (connected to LT circuit)
Temperature regulating valve
Safety valve
The above mentioned eqiupment is mounted on a frame with corresponding
fittings, completely piped and wired.

EGD53 AA010

040.050.080

Fuel injection nozzle cooling system

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 19 of 58

Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Item
040.060.040

Qty Description
1

Set of heavy fuel fuel oil supply pumps


(1x for service + 1x as stand by)
capacity approx. 20 m/h each, with motor 15 kW, with dirt trap and safety
valve.

Set of Diesel oil supply pumps,


(1 x service + 1 x stand-by), capacity approx. 25 m/h each, with motor 11 kW,
with dirt trap and safety valve.

Heavy fuel oil filter module


consisting of:
Automatic backwash filter for fuel oil approx. 0.025 mm, with attached
differential pressure contact indicator, steam heated
Flushing tank
The above equipment mounted on a frame, complete with pipes.

Diesel oil duplex filter


mesh width 0.025 mm with attached differential pressure contact indicator

END55 AP030

040.060.050
EGD53 AP020

040.060.060
EGD53 AT050

040.060.080

4.2.7
040.070.010

Starting air receiver


capacity 5000 l, working pressure 30 bar, with valve head, fittings, pressure
gauge, supports and retaining bracket. The starting air receivers are connected
in parallel, each one can be isolated from the system by shut-off valves.
The capacity of the starting air receivers is designed for 3 starts of one engine
without refilling. After a longer standstill of the engine a slow turn manoeuvre is
required which needs additional starting air. 1 slow turn manoeuvres are
considered in dimensioning of total capacity of the starting air receivers.

Automatic draining equipment for starting air receiver

Compressor module
consisting of 2 compressors with eletric motor, 30 bar pressure, capacity 172
m/h each at 20C and 1013 mbar barometric pressure, with suction filter, air
cooled, intermediate and final cooler, oil and water traps, electro-magnetic
water drain and switch and control device.
Module complete with three-phase motor 45 kW, flywheel and flexible coupling.
Equipment mounted on a skid for resilient mounting.

Pressure reducer for control air


with water trap, dirt trap and safety valve. One in operation plus one in standby.
The pressure reducer is installed in the 30 bar air line, the pressure is reduced
to 7 bar for providing control air to the engine and accessories.

SCB71 BB010

040.070.030

Starting air system

SCA71 AT020

040.070.040
SCA71 AN010

040.070.060
QFA71 AA010

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 20 of 58

Nababganj Power Plant - 55MW


Section 4 - Mechanical scope

Qty Description

Item
040.070.070

Control air drier


Dehumidification of the control air. Complete system with
thermometer for dew point temperature indication
automatic condensate discharge

Control air tank for pump house


content 120 l, vertical tank with safety valve, pressure gauge and shut-off
valve.
The control air tank to be installed in the pump house.

Start-up air blower

QFB72 AT020

040.070.080
QFB72 BB010

040.070.140 -1

4.3

4.3.1
060.005.010

MJR65 BS010

4.3.2
060.140.020

Exhaust gas system

Exhaust gas silencer


Exhaust gas silencer:
Silencer for installation outside of the power house,
Technical features:
Reactive and/or absorptive attenuation principle
Noise attenuation
approx. 25 dB(A)
Total pressure loss
< 10 mbar
Material of main components
S235JR
Absorptive material, if any, within special cushions retained by perforated
plates
Scope of supply for silencer including:
Corrosion protection of non-insulated external surfaces
Support brackets and fixing accessories for installation on roof or in steel
structure
Delivery loose, without counterflange and insulation material
Insulation works by Third Parties according to engineering specification

Insulation material for exhaust gas duct


insulation material for silencer
incl. insulation material and sheathing

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 21 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

5
Item

Qty Description

5.1

5.1.1
070.010 -1

5.1.2
070.020 -1

Electrical scope

Control and monitoring system

Genset Interface Panel (GIP)


Genset Interface Panel (GIP)
The genset interface panels are arranged for floor mounting with cable insert
from backside into plinth. Design as steel frame construction, totally closed,
front door with rubber gasket. The panels are equipped with fans, thermostat,
air filters and anti-condensation heating. The panels are with panel light and
electrical outlet.
Dimensions of each panel:
Width
approx. 800 mm
Height
approx. 2,000 mm
Depth
approx. 600 mm
Plinth
approx. 200 mm
protection class IP 42
structural painted to RAL 7035
plinth painted to RAL 7022
labels: white, with black standard-type letters, design according to DIN EN
60439-1, IEC 60439-1 and ISO 8528, Part 4.
Control equipment:
AC power supply input for panel equipment
AC UPS power supply input for control and generation of DC 24V
1 x AC UPS Voltage / DC 24 V power supply unit for PLC equipment
Emergency stop push button with interlocking relais with positively driven
contacts and external reset terminals. Function: engine shut down and
engine aux. stop
PLC equipment (Siemens ET200)
1 PROFIBUS connection to Interface Cabinet
1 PROFIBUS connection to EAP (Engine Auxiliary Panel)
1 Interface module to EDS-D system
Integrated devices:
AVR with power factor regulation (item 025.020.050)
1 EDS-D system

Genset control panel (GCP)


Genset control panel (GCP)
arranged for floor mounting, metal enclosed cubicle, steel frame construction,
totally closed with ventilation slots, front door with rubber gasket
Dimensions each panel:

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 22 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
Width:
approx. 800 mm
Height:
approx. 2000 mm
Depth:
approx. 600 mm
with panel fan incl. thermostat and filter for each panel
with panel light, incl. electrical outlet
with heating resistance humidity controlled
protective system IP 42
structural painted to RAL 7035
instruments: frame size: 96 x 96 mm, scale 90, class 1,5
labels: white, with black standard-type letters, design according to DIN EN
60439-1, IEC 60439-1 and ISO 8528, Part 4.
located in control room, cable insert from bottom
MEASURING:
1 Voltmeter
1 Voltmeter selector switch for generator, 3 positions
3 Ammeters
1 Power factor meter 0,5-1-0,5*
1 MW-meter for connecting on transducer*
1 MWh-meter with pulse output*
1 Measuring transducer for active power*
1 Measuring transducer for reactive power*
1 Measuring transducer for current*
1 Measuring transducer for voltage*
1 Measuring transducer for power factor*
1 Measuring transducer for frequency*
* can be integrated in one device
1 Set of test terminals for performance test
1 Set of measuring and control circuit MCBs

SYNCHRONISING:
1 Automatic synchronizing unit with black busbar possibility door mounted
1 Synchrocheck relais with black busbar possibility
1 Key selector switch "GCP-SCADA"
1 Selector switch for GCP synchronizing "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Push button "CB ON"
1 Push button "CB OFF"
1 Switch "frequency lower / 0 / frequency higher"
1 Switch "voltage lower / 0 / voltage higher"

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 23 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
1 Mimic diagram equipped with position indicator for generator circuit
breaker
1 Mimic diagram equipped with position indicator for alternator earthing CB
with push buttons "ON / OFF"
ALTERNATOR PROTECTION:
digital protection relays, with following protection functions:
Stator earth fault (59N)
Directional earth fault (67N), with cable current transformer
Over-current (51)
Short-circuit (50)
Negative sequence (46)
Differential current (87 G)
Loss of excitation (40)
Reverse power (32)
Over-/under-frequency (81)
Under-voltage (27)
Over-voltage (59)
Over-excitation (24)
Loss of excitation (40)

realized in AVR
realized in AVR as backup

CONTROL:
AC Supply input for panel equipment (fan, socket, anti-condensation
heating).
AC Supply input from UPS for control
Necessary set of mcbs
Necessary set of contactors, relays, transducers, terminals a.s.o.
Fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list.
All devices marked on device and mounting plate acc. circuit diagram.
1 Panel inside fixed list of mcbs and related functions.
Emergency stop push button with interlocking relays with connection to the
positively driven contacts and external reset terminals in ECP, function:
engine shut down
Spare terminals 10% of installed
PLC Part:
with Siemens Simatic S7-400
1 Power supply unit
1 CPU
1 Communication processor for industrial Ethernet
*Digital input boards with 32 inputs.
*Digital output boards with 32 outputs.
*Analogue input boards with 16 inputs.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 24 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
1 PROFIBUS connection to ECP (Engine Control Panel)
1 Siemens Operator Panel
1 MPI connection from CPU to Operator Panel
*Number of boards as required (15 % spare).
Data link to Central Supervisory System / Common Control Panel: Ethernet
SOFTWARE:
consisting of:
Start/stop and monitoring program for genset auxiliaries (automatic /
manual)
Start and stop program for engine
Generator active power monitoring
Generator current monitoring
Generator voltage monitoring
Generator power factor monitoring
Generator frequency monitoring
Generator circuit breaker control / Synchronizing release
Engine load regulation
Engine analogue value monitoring
Storage of analogue values
Overload monitoring (> 100 % load, load reduction)
Alternator winding temperature protection
(49)
(alternator equipped with 6 Pt100 sensors)
Alternator bearing temperature protection
(39)
(bearing equipped with Pt100 sensor)
In case of trouble, the indication of arisen failures will be indicated in sequence
of incidence with additional indication of time, when it happened.

5.1.3
070.030 -1

Common control panel (CCP)


Common control panel (CCP)
arranged for floor mounting, metal enclosed cubicle, steel frame construction,
totally closed with ventilation slots, front door with rubber gasket.
Dimensions:
Width
approx. 2000 mm
Height
approx. 2000 mm
Depth
approx. 600 mm
with panel fan incl. thermostat and filter
with panel light, incl. electrical outlet
with heating resistance thermostat controlled
protective system IP 4x

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 25 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
structural painted to RAL 7035
instruments: frame size: 96 x 96 mm, scale 90, class 1,5
labels: white, with black standard-type letters,
design according to DIN EN 60439-1, IEC 60439-1 and ISO 8528, Part 4.
Located in control room, cable insert from bottom
MEASURING:
For 1 outgoing to step-up transformer:
Voltmeter
Voltmeter selector switch, 3 positions
3 Ammeter
1 Power factor meter 0,5-1-0,5*
1 MW-meter for connecting on transducer*
1 Measuring transducer for active power*
1 Measuring transducer for reactive power*
1 Measuring transducer for current*
1 Measuring transducer for voltage*
1 Measuring transducer for power factor*
1 Measuring transducer for frequency*
* can be integrated in one device
for 1 MV bus bar:
1 Voltmeter
1 Voltmeter selector switch, 3 positions
1 Measuring transducer for voltage
1 set of test terminals for performance test
1 set of measuring and control circuit MCBs
SYNCHRONISING
1 automatic synchronizing unit for outgoing to grid,
1 automatic synchronizing unit for LV circuit breaker to station transformer
1 Key selector switch "CCP-SCADA"
1 Selector switch for CCP synchronizing: "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Mimic diagram equipped with position indicator and push buttons ON/OFF
for each MV circuit breaker (except alternator CBs) and synchronisable LV
CBs
1 Control switch "frequency lower / 0 / frequency higher"
1 Control switch "voltage lower / 0 / voltage higher"
PROTECTION

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 26 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
1 multi function protection relay for station transformer, with:
Short-circuit (50)
Overcurrent (51)
Earth fault (50N/51N)
1 multi function protection relay for outgoing feeder to step-up transformer,
with:
Short-circuit (50)
Overcurrent (51)
Earth fault (50N/51N)
Over/under voltage (59/27)
Over/under frequency (81)

CONTROL:
consisting of:
AC supply input for panel equipment (fan, socket, anti-condensation
heating)
AC UPS input for control
Necessary set of mcbs with short circuit withstands 10kA for values <= 20A
and 15kA for values > 20A
Necessary set of contactors, relays, transducers, terminals a.s.o.
Horn for alarm door mounted, fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list
All devices marked on device and mounting plate acc. circuit diagram
1 Panel inside fixed list of mcbs and related functions
1 Set of push buttons: lamps test, horn off, reset etc.
1 Set of control lamps: common aux. fault etc.
1 Control equipment for detection of mains fault
PLC Part:
Hardware with Siemens Simatic S7-400
Consisting of:
1 Power supply unit
1 CPU41_
1 Communication processor for industrial ethernet
*Digital input boards with 32 inputs
*Digital output boards with 32 outputs
*Analogue input boards with 16 inputs
1 Siemens Operator Panel OP 677 19"
1 MPI connection from CPU to OP 677 19"
1 Profibus connection to CAP
1 Profibus connection to CAPP
Data link to Central Supervisory System: Ethernet.
*Number of boards as required (15 % spare)

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 27 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Item

Qty Description
Software:
consisting of:
Control (switch ON/OFF, interlocking, release) of all motor operated circuit
breakers in MV switch gear and LV main distribution
Control of all plant auxiliaries acc. to power station design "AutomaticManual"
Plant power management acc. to remote or local demand
Load sharing program for load balance of the engines, including monitoring
of nominal load and reverse power
Control for start and stop of the gensets depending on load demand.
Island operation features
Load shedding program, in case of overload and underfrequency
Control for earthing resistors with selector switch "Automatic-Manual"
Mimic diagram for earthing CB with control lamp "ON"
Control for interlocking of earthing CBs (only one CB is on)
Mimic diagram for all motor driven CBs

5.1.4
070.040 -1

Operation and monitoring system


CENTRAL SUPERVISORY SYSTEM
Automation control system for supervision and control with 2 Server PCs and 3
Operator Station PCs for supervision:
Hardware:
2 Server PC with CPU with appropriate performance and memory capacity,
with state of the art operating system, with hard disk, CD-ROM, interfaces 2
x serial, 1 x parallel, state of the art graphic board, 3 Ethernet connections
standard keyboard (english)
redundant remote control via modem
3 Operator Station PCs with CPU with appropriate performance and
memory capacity, with state of the art operating system, with hard disk, CDROM, interfaces 2 x serial, 1 x parallel, USB, state of the art graphic board,
ethernet connection
standard keyboard (english) and mouse
19" Monitor (TFT)
one color inkjet desk top printer, DIN A4 with cut sheet feeder
one black/white laser desk top printer, DIN A4 with cut sheet feeder
Ethernet switches
Software:
for 3 generating sets installed on each PC, consisting of:
complete overview of the power station
presentation of genset with analog value indication
single line diagram of the power station
overview of the lube oil system
overview of the cooling water system

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 28 of 58

Nababganj Power Plant - 55MW


Section 5 - Electrical scope

Qty Description

Item

overview of the fuel system


overview of the intake air system
overview of the exhaust gas system
overview of the steam generation system
presentation of these values in monthly bar diagram
presentation of 32 analog values as a line diagram of the last 24 hours (8
values in one diagram simultaneously)
presentation of 32 stored analog values as a line diagram at days before (8
values in one diagram simultaneously)
documentation of fault indications and operation signals as short term / long
term history.

5.1.5
070.060.010 -1

Plant sensors for piping


Plant sensors for piping
Sensors and instrumentation for visualization of operating conditions
transmitted via electrical signals (no local sensors without any wiring)
Scope of supply:
Sensors and instrumentation connected to pipes (connecting pipes between
modules) which are not included neither in the scope of the Diesel engine nor
in any module or component of the plant.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 29 of 58

Nababganj Power Plant - 55MW


Section 6 - Miscellaneous

6
Item

170.010.010 -1

Miscellaneous

Qty Description

6.1

Plant service and protection systems

6.2

Documentation

Engine, turbocharger and plant documentation


in paper edition, consisting of:
Operating instructions and maintenance schedule for engine and turbocharger
Working Instructions
Spare parts catalogue
Tools and spare parts list
Workshop test acceptance certificate for engine and turbo-charger
Set of documentation for the plant accessories and
Set of documentation for control and monitoring accessories (after
commissioning)
Additionally the above mentioned documents will be handed over in PDFformat on CD or DVD. The documentation will be in English language and in
MAN Diesel & Turbo Standard format (duplex printed).

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 30 of 58

Nababganj Power Plant - 55MW


Section 7 - Tools, spare and wear parts

7
Item

Qty Description

7.1

7.1.1
015.010.010

Tools, spare and wear parts

Tools and spares

Engine tools
Set of standard and special tools for the engine
required for servicing and inspection of the engine, consisting of:
BASIC TOOLS
Eye bolt, socket wrench insert with adapters, screw driver inserts, torque
spanners
HYDRAULIC TOOLS
Pneumatically driven hydraulic high-pressure pump with hyraulic bolt
tensioning devices
MEASURING TOOLS
Valve seats in the inlet and exhaust valve seat rings
Elongation of the connecting rod bolts
TOOLS FOR INJECTION
Adjusting device for the fuel injection pumps
Hydro pneumatic injection tester and cleaning tool for the fuel injection
valves
TOOLS FOR GOVERNOR
Tools for the speed governor
GENERAL
Piston ring expander
Cleaning device for the injection and starting valve seats in the cylinder
heads
DEVICES
Hydraulic lifting and lowering device for the main bearing caps
Supporting device for the running gear
Mounting and removing devices for:
Valves in the cylinder heads
Inlet and exhaust valve springs
Fuel injection pumps and their drive
Springs of the fuel injection pumps
Sealing rings of the fuel injection pump elements
Pistons including insertion bush
Cylinder liners
Fire ring
Connecting rod bearing caps
Crankshaft and connection rod bearing shells
Connecting rods
Suspension devices for:

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 31 of 58

Nababganj Power Plant - 55MW


Section 7 - Tools, spare and wear parts

Item

Qty Description
Rocker arm casing
Cylinder head
Fuel injection pumps
Connection rod shank
MILLING AND GRINDING TOOLS
Milling device for the fuel injection valve seat in the cylinder heads

015.010.020

Crank web deflection measuring device

015.010.080

Electric valve cone grinder


for the exhaust valves, make HUNGER

015.010.090

Electric valve seat grinder


for the inlet and exhaust valve seats (alternating current 230V)

015.010.110

Electronic firing pressure gauge 250 E

015.010.182

Assembly and reversing device for the cylinder heads

015.010.370

Set of tools for turbocharger


including 1 set of blocking / closing device

7.1.2

Engine spare and wear parts

015.020.010

Set of spare parts for turbocharger

015.020.020

Set of engine standard spare parts


for engine type 18V48/60TS, consisting of:
Piston:
1 Set of compression and oil scraper rings
Cylinder head:
1 Valve seat insert for inlet valve with round seal ring
1 Valve seat insert for exhaust valve with round seal ring
1 Valve guide with round seal ring
Inlet valve:
1 Inlet valve, complete
Exhaust valve:
1 Exhaust valve, complete
Operation/Monitoring:
1 Three-way solenoid valve
1 Pressure reduction valve
Fuel injection pump with drive:
1 Pump plunger with barrel (pump element)
1 Set of seal rings for fuel injection pump
Fuel injection valve:
1 Fuel injection valve, complete

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 32 of 58

Nababganj Power Plant - 55MW


Section 7 - Tools, spare and wear parts

Qty Description

Item

3 Fuel injection nozzles with needle and guide


3 Sets of round seal rings for injection valve
Fuel injection pipe:
1 Fuel injection pipe with connection parts (without threaded piece)
Seals and round seal rings:
1 Set of seals and seal rings for 1 cylinder
Sealing material:
1 Set of sealing material.
015.020.070

Spare parts for operating and monitoring the engine

015.020.140

Set of spare parts for SACOS

015.020.170

Spares for oil mist detector

7.1.3

Plant tools

015.030.025

Tools for nozzle cooling water unit

015.030.090

Mobile strainer cleaning unit


for lube oil and heavy fuel oil automatic filter, consisting of:
Tank
High-pressure pump
Pump protecting filter
Microfilter
Cleaning gun with high-pressure hose
Cleaning liquid

7.1.4
015.040.020 -1

Plant spares
Set of spare parts for alternator
consiting of:
1 Set of diodes; varistor (for one generator)
1 PC PT100 for bearing

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 33 of 58

Nababganj Power Plant - 55MW


Section 8 - Services

8
Item

Qty Description

8.1

8.1.1
205.010 -1

Services

Quality Management, Quality Assurance

man hours Quality Planning


Establishing of a Quality Plan
MAN Diesel & Turbo has implemented a Quality Management System that
conforms to ISO 9001 and ISO 14001 environmental standards. The integrated
quality and environmental management manual is applied to all internal
process steps to assure MAN Diesel & Turbo's grade of quality for our engines
as well as for equipment delivered by subsuppliers.
An individual quality plan will be issued, containing order-specific outlines of the
quality standard related to quality assurance and quality documentation. In
addition, individual processes are scheduled, deliveries are defined and test
plans are assigned to the components to be suppiled. Factory/Site Acceptance
Tests follow the individual items of this plan.
The electronic version of the documentation shall consist of:
Project specific Quality Plan
Inspection and Test Plans
Inspection and Test Records
The above mentioned documents will be handed over in PDF format on
CD/DVD. The documents will be in English language and in MAN Diesel &
Turbo standard format.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 34 of 58

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Section 8 - Services

Qty Description

Item

8.2

Project engineering

8.2.1

System engineering

210.015.010 -1

System engineering
MAN will engineer the standard systems of the power plant and supply the
design data required for specification of the concerned equipment
Design of the lube oil, cooling water, fuel, intake air and exhaust gas
systems
Heat recovery system for auxiliary consumption
Adaption of the engine configuration to site conditions
The results of the system engineering are dimensioning data such as
consumption, pressures, flow rates, temperatures, etc. and technical
requirements at interfaces which will be used for ordering of the equipment.
MAN will execute P&I Diagrams of all mediums required for the operation of the
electrical power generating equipment (i.e. lube oil, cooling water, fuel)
including all relevant pipe sizes.

210.015.020 -2

Basic Design criteria - Engineering Tankfarm


Basic dimensioning of tanks
Definition of heating requirements
Recommendation for tanks incl. generic standard drawings for tanks
and heating device
Recommendation for instrumentation of tanks

8.2.2
210.020 -1

Mechanical project engineering


Mechanical project engineering
MAN will execute following order drawings:
Power house layout drawing

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Nababganj Power Plant - 55MW


Section 8 - Services

Item

Qty Description

8.2.3
210.022 -1

8.2.4
210.033.010

8.2.5
210.040 -1

3D modelling
3D modelling
Based on the engineering services mentioned above MAN Diesel & Turbo will
execute a 3D modelling for Powerhouse.
As an outcome of the finished 3D model following drawings will be provided.
General drawings for mechanical erection of the plant:
Equipment location plan
Support location plan
Main cable tray plans
Guidance drawings for the preparation of plant steel works:
Pipe support drawings
Additional steel support drawings
Drawings for preparation and execution of piping works:
Pipeline installation plans
System isometric drawings
Pipe isometric drawings

Calculation of genset foundation


Design of the genset foundation base
Based on the genset foundation drawing mentioned above, MAN will execute
civil design works for the genset foundation.
As an outcome of the civil design works MAN will prepare following
documentation:
General arrangement drawing
Reinforcement drawing
Steel bending and quantity list
Foundation calculation
Short construction manual.
Calculation of the foundation is based on the soil bearing capacity as per
section 1 and does not consider engineering or design for piling.

Engineering of auxiliaries
Engineering of auxiliaries
Based on the standard system engineering mentioned above, MAN will define
and engineer all offered equipment.

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Nababganj Power Plant - 55MW


Section 8 - Services

Qty Description

Item

8.2.6
210.060 -1

8.3

8.3.1

Electrical engineering
Electrical engineering
establishing of the electrical documentation of the plant, consisting of:
Technical specification of electrical equipment
Electrical cabinet drawings
PLC architecture / schematic diagrams
Single-line diagrams for MV and LV system
List of measuring and control devices (plant)
List of Electrical Consumers

Logistics

Transportation of equipment

220.020.050 -1

Sea transport to CIF Mongla, not unloaded

220.020.090 -1

Engine lifting device (on loan basis)


MAN Diesel & Turbo will deliver the engine together with an engine lifting
device. This equipment is required for transport and installation purpose only
and shall be returned to MAN Diesel & Turbo once installation of the engines /
generating sets is over.
The customer shall cover the cost for return transport to MAN Diesel & Turbo's
workshop in Augsburg and shall also arrange for temporary import permission
of the device (if necessary).

8.4

8.4.1

Site activities

Supervision of installation

230.030.040 -1

34 man days monitoring of mechanical installation


The MAN Advisor joins the placing of the gensets on the foundation, alignment
as well as installation of the offered auxiliary equipment to implement the MAN
Diesel & Turbo quality standard. After completion, a final check of all systems
will be done.

230.030.060 -1

13 man days of electrical equipment erection

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Section 8 - Services

Qty Description

Item

8.4.2

Commissioning

230.110.010 -1

75 man days commissioning of engine by technician


The technician will assist the commissioning engineer in performing all
mechanical pre-tests, signal testing, starting up the genset, collecting of
operational data and adjusting of engine parameters.

230.110.020 -1

75 man days commissioning of engine by engineer


The commissioning engineer will perform all mechanical and electrical pre-tests
and starting up of the individual auxiliary systems. The commissioning engineer
is responsible for running-in the engine according to manufacturers
instructions. He verifies functional tests of the engine and plant control and
safety system. Additionally he will assist the measurement team during the
execution of performance tests.

230.110.040 -1

75 man days commissioning LV/Control (SaCoS)

230.110.200 -1

15 man days commissioning alternator


One commissioning engineer from the manufacturer will commission the
alternator according to the manufacturers instruction. He will check the correct
installation as well as the function of the alternator protection and control
system.

230.110.210 -1

man days commissioning lube oil seperators

230.110.210 -2

man days commissioning separators


One commissioning engineer will verify the correct installation and set the
separator into operation according to manufacturers instruction.

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Section 8 - Services

Qty Description

Item

8.4.3

Site Acceptance Test (SAT)

230.120.010 -1

Performance test
Specialists from MAN Diesel & Turbo will perform measurements to
demonstrate the guaranteed values according to MAN Diesel & Turbo test
procedures. The measurements will be done by our engineers in cooperation
with the customers operating personnel.
Output at site:
Measurements are taken at by using an external high precision power meter
Type Zimmer LMG 450.
Fuel oil consumption:
Measurements and calculations of the fuel oil consumption will be carried
out in line with ISO 3046, ISO 15550 and MAN standard procedures.
Measuring equipment is an external high-precision mass flow meter type
Endress+Hauser Promass 83, which is temporarily installed on the fuel oil
booster module. The duration of the test has to be adapted to the local
availability of constant load. As a guideline, 3 tests of 2 hours each could be
performed. The determination of the lower calorific heat value of the fuel oil
used will be carried out at the MAN laboratory in Augsburg.
Lube oil consumption:
The measurements and calculations of the lube oil consumption will be
carried out in line with ISO 3046, ISO 15550 and MAN standard procedures
(engine running in). Due to the required measuring time being minimum 24
hours, lube oil consumption measurement will continue after the fuel
consumption test.

230.120.040 -1

man days exhaust gas emission test


MAN Diesel & Turbo will carry out tests and measurements to verify
compliance of the engine emissions with the contractually specified criteria.
This is done by MDT own staff.

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Section 8 - Services

Item

Qty Description

8.5

8.5.1

240.010 -1

Project services

Factory training (mechanical)


Optional service
Factory training (mechanical)
Basic mechanical training course for up to 6 plant operators at the PrimeServ
Academy. Duration of the training is 5 days, training without traveling
expenses, boarding and lodging. The training language will be English.
Seminar contents:
Welcome and general introduction:
Introduction to the specified engine type
Safety and special tools
Handling of manuals and work cards
Hydraulic tensioning tools
Running gear maintenance
Fuel injection system
Lube oil system
Pneumatic system
Engine starting system
Cooling water system
Operating data of systems on engine
Turbocharger basics
Turbocharger maintenance
Introduction to Engine Control System
Operation of Engine Control System
Operating and maintenance experience
Identifying minor faults and troubleshooting
Execution of maintenance tasks defined byMAN Diesel & Turbo
instructions.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.

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Section 8 - Services

Item

Qty Description

8.5.2

240.015 -1

Factory training (electrical)


Optional service
Factory training (electrical)
Basic training in electrical operation up to 6 participants. The training consists
of 5 working days, training without traveling expenses, boarding and lodging.
A detailed training schedule for the training program will be elaborated by the
PrimeServ Academy at least fourteen days prior to course implementation. The
training language will be English.
The course includes theoretical training as well as field exercises:
Maintenance procedures on alternators, transformers, switchgears and DC
systems.
Review of single line diagrams, switchgear and relay maintenance and
trouble shooting,
Introduction to the instrumentation and control system, such as e.g. control
fundamentals, sensors, transmitters, instrumentation and control systems.
The course will be held by professional trainers, dedicated to training only,
using multi-media equipment. Each participant will receive a personal copy of
the full course documentation.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.

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Section 8 - Services

Item

Qty Description
Additional site activities
The above mentioned site services are based on our experience and cover the
normal supervision duration of a standard power plant. In case this project
requires additional supervision or commissioning services, we are able to offer
further supervision services based on the following conditions.
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Engineer as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays
EUR 1,100.00
Daily allowance per calendar day
with free accommodation
EUR
85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays
EUR
200.00
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Technician as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays
EUR
880.00
Daily allowance per calendar day
with free accommodation
EUR
85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays
EUR
160.00
Should any evaluation costs be made in the workshops, then these will be
added to the invoice.
Travelling time will be charged at above mentioned prices. Travelling and
accommodation costs will be invoiced as incurred.
Value added tax
The above mentioned rates, resp. expenses, are quoted without VAT. The
corresponding VAT (turnover tax) will have to be added to those amount
according to the legal regulations which apply.

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Nababganj Power Plant - 55MW


Section 9 - Requirements and limitations

9
9.1

Requirements and limitations


Quality requirements for operating media
MAN Diesel engines are designed for continuous operation on the operation
media as listed below. Project specific system layout for the respective
operating media are mentioned in the respective chapters of our offer.
Compliance with environmental regulations (e.g. World-Bank Guidelines for
stack emissions) cannot be stipulated and has to be checked for the operating
media that will be used for the project.

9.1.1

Lube oil
Use of engine lube oils according to the approval list of MAN Diesel & Turbo.
More detailed information on the lube oils approved by MAN Diesel & Turbo is
available in the engine manuals.
Requirements for viscosity:
Viscosity-class (40)
SAE40
Requirements for Base Number (BN):
TBN (Total Base Number),
if sulphur concentration < 1.5% wt.
30 mg KOH/g oil
if Sulphur concentration > 1.5% wt.
40 mg KOH/g oil
Please note that our cooling systems are designed to operate with the above
mentioned lube oil class SAE40 only. Operation of the plant with other lube oils
requires a detailed modification in the cooling systems and additional equipment
cost.

9.1.2

Cooling water
The engine and radiator cooling water must be carefully selected, treated and
controlled. The treatment with an anti-corrosion agent has to be effected before
the first commissioning of the plant. During subsequent operations the
concentration specified by the engine manufacturer must always be ensured.
The MAN operating instructions contain the additive brands that are approved
by the manufacturer.
The characteristics of the water used for engine cooling must be within the
following limits:
Type of water
preferably distilled water or freshwater,
free from foreign matter
4
Total hardness
< 10dH
pH-value
6.5 - 8
Chloride ion content
max. 50 mg/l
Silicid acid
max. 50 mg/l
Not to be used:
Sea water, brackish water, brines
industrial waste water and rain water

1 dH (German hardness) = 10 mg CaO in 1litre water


= 17.9 mg CaCO3/litre
= 0.357 mval/litre
= 0.179 mmol/litre

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Section 9 - Requirements and limitations

9.1.3

Water for separators


The water for separator operation must be carefully selected, treated and
controlled. The characteristics of the water used must be within the following
limits:
Type of water
preferably distilled water or freshwater,
free from foreign matter
5
Total hardness
< 6dH
pH-value
> 6.5
Chloride ion content
< 50 mg/l
TSS
< 10 mg/l
Not to be used:
Sea water, brackish water, brines
industrial waste water and rain water

9.1.4

Diesel fuel oil

9.1.4.1

Fuel system related characteristic values


Diesel fuel oil (DFO) based on ISO F- DMB. (ISO 8217-2010)
The usability of the DFO depends on its conformity with the key properties listed
below:
42,250 kJ/kg
Lower calorific value (LCV)
3
900 kg/m
Density at 15 C
2
2.0 11 mm /s
Kinematic viscosity at 40C
< 0 C
Pour Point, winter quality
< 6 C
Pour Point, summer quality
> 60 C
Flash point (Pensky Martens)
0.10 % wt.
Total sediment fraction
< 0.3 % vol.
Water content
< 2.0 % wt.
Sulphur content
< 0.01 % wt.
Ash content
< 0,3 % wt.
Coke residue (MCR)
> 35
Cetane number or cetane index
<
2
mg/kg
Hydrogen sulphide
< 0.5 mg KOH/g
Total acid number
3
< 25 g/m
Oxidation stability
< 520 m
Lubricity (wear scar diameter)
<1
Copper-strip test
If the above mentioned fuel oil specification is not met, it can only be used in
case of fuel treatment.

9.1.4.2

Diesel fuel oil properties related to site conditions


2

Required kinematic viscosity at engine inlet:


2,5 14 mm /s
To meet the Diesel oil requirements at engine inlet the Diesel oil provided must
be in a range between minimum viscosity and maximum viscosity as specified

1 dH (German hardness) = 10 mg CaO in 1litre water


= 17.9 mg CaCO3/litre
= 0.357 mval/litre
= 0.179 mmol/litre

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Section 9 - Requirements and limitations

bellow, considering project-specific ambient conditions (minimum air


temperature Tamb min. / maximum air temperature Tamb max. plus T = 10 K):
2
Min. kinematic viscosity:
2.5 mm /s at 50 C
2
Max. kinematic viscosity:
14 mm /s at 10 C
MDT is recommending a fuel management suitable for seasonally occurring
temperatures, i.e. subsequently to the requirements above it might be
necessary to provide two different Diesel oil qualities for summer season and
winter season.
In case the viscosity limits as stated above cannot be met, a special Diesel oil
cooling system respectively a Diesel oil heating system is required and can be
offered upon request.
9.1.5

9.1.5.1

Heavy fuel oil


The HFO specified in the following chapters is the worst-case fuel that Diesel
engines can operate satisfactorily.
Fuel system related characteristic values
The fuel system is designed to operate based on the following fuel oil
specification based on ISO 8217-2010:
Lower calorific value (LCV)
40230 kJ/kg
2
Viscosity (at 50C)
up to 180 mm /s
3
Density (at 15C)
max. 1010 kg/m
Sulphur content
up to 3.4%-wt.
Ash content
up to 0.15%-wt.
Flash point
min. 60 C
Pour point
max. 30 C
Coke residue (Conradson)
max. 20 % wt.
Vanadium
max. 450 mg/kg
Water
max. 0.5 % vol.
Sediment (potential)
max. 0.1 % wt.
Aluminium and silicon (total)
max. 60 mg/kg
Total acid number
max. 2.5 mg KOH/g
Hydrogen sulphide
max. 2 mg/kg
Asphaltene content
max. 2/3 of coke residue
% wt (Conradson)
Sodium
Sodium < 1/3 vanadium,
Sodium < 100 mg/kg
CCAI number
max. 870
Current fuel oil characteristics is not sufficient for estimating the combustion
properties of the fuel oil. This means that service results depend on oil
properties which cannot be known beforehand. This especially applies to the
tendency of the oil to form deposits in the combustion chamber, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause
difficulties.
The fuel must be free of admixtures not based on mineral oil, such as coal oil or
vegetable oils, free of tar oil and lubricating oil, free of any chemical waste,
solvents and polymers.

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Nababganj Power Plant - 55MW


Section 9 - Requirements and limitations

9.1.5.2

Treated heavy fuel oil at engine inlet


Inorganic foreign particles
<20 mg/kg
(incl. catalyst residues)
(aluminium + silicon content < 15 mg/kg)
particle size: < 5 m
Water
< 0.2% vol.

9.1.6

Intake air
The quality and the condition of the intake air (combustion air) exert great
influence on the engine output as well as on the engine's lifetime.
For this reason, effective cleaning of the intake air and regular
maintenance/cleaning of the air filter are required.
The concentrations before the turbocharger inlet must not exceed the following
limiting values:
Dust (sand, cement, CaO, Al2O3 etc.)
max. 5 mg/Nm
Chlorine
max.1.5 mg/Nm
Sulfur dioxide (SO2)
max.1.25mg/Nm
Hydrogen sulphide (H2S)
max.15 mg/Nm

9.2

Limits of supply

9.2.1

General remark
The Limits of Supply are to be read in connection with the offered scope of
supply as per the technical specification.
All equipment comes with steel frames or mounting plates and with bolts, studs
and screws to install the equipment on the foundations or elevated platforms /
walkways.
Any steel supporting structures, steel mounting elements, etc. necessary to
install the equipment / modules / auxiliaries are not included in the scope of
supply of MAN Diesel & Turbo.

9.2.2

Generating sets
Mechanical:
Pipe connection terminal on the engine to connect the engine to various
pipes
Electrical:
Terminal box of the alternator
Civil:
Steel foundation frame with frame stoppers and leveling screws; grouting
material (pagel)

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Nababganj Power Plant - 55MW


Section 9 - Requirements and limitations

9.2.3

Engine and plant related auxiliaries, modules, equipment


and tanks
Mechanical:
Flanges and counter flanges on the modules / auxiliaries / equipment for
connection to the various system pipes (e.g. fuel, lube oil, water, sludge,
steam, condensate, pressurized air)
Electrical:
Terminal boxes on the modules / auxiliaries / sensors for connection to the
power and control cables

9.2.4

Electrical equipment / Engine and plant control system


Connectors on Genset Interface Panel (GIP) and Genset Control Panel
(GCP) for bus cables (Profibus)
Connectors for power supply on GIP and GCP

9.2.5

Engineering
Civil: n/a
E&M: Inside power house
PIDs: For fuel, intake air, exhaust gas, cooling water, lube oil.

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Nababganj Power Plant - 55MW


Section 10 - Operation and maintenance

10
10.1

Operation and maintenance


MAN Diesel & Turbo Service Worldwide
For all engines delivered by us or built according to our design, MAN Diesel &
Turbo offers high-quality service 24 hours a day and around the world.
Therefore, our customers may rely on assistance through our service team
during the entire life-time of their engine plant.
The scope of services and products covered by the MAN Diesel & Turbo
Service network comprises the following essential features:
All over the globe, along the major shipping routes as well as in the most
thriving economies, the MAN Diesel & Turbo Service team is near you! This
ensure 32 service centres, 49 authorised workshops, 24 spare parts stocks and
70 agencies, which provide the best possible care for your plant.
If necessary, a swift, around-the-clock spare parts supply permits delivery of
parts, usually within one day from the receipt of your order.
Our specialists, located both at our global service bases and in our Augsburg
headquarters, offer free-off-charge counselling by phone. From among them, a
stand-by team of particularly experienced service personnel will render
competent assistance; 24 hours a day and 365 days a year!
Original, high-quality spare and wear parts ensure the safe, reliable and
economic operation of your engine plant; at a reasonable price! This also
applies to our inexpensive reconditioning service.
If you wish to combine utmost operational reliability with certainty regarding the
future working expenses of your plant, you may take advantage of our
maintenance and operation contracts. We provide the required exchange parts
as well as the connected services over the requested contract period at exactly
calculated costs.
Even the best state-of-the-art engines require a qualified service, which we
have been offering for over a century, now.
Make use of our experience!

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 11 - Standards, Guidelines and Drawings

11

Standards, Guidelines and Drawings

11.1

Applicable standards
All materials, equipment and services mentioned in this quotation comply with
the respective standards and codes of the country of manufacture.
In particular, equipment supplied from EU countries complies, as far as
applicable, with the following standards and codes:
ISO International Standards Organisation
IEC International Electro technical Commission
EN standard - European Institute for Standardisation
Manufacturers QA/QC System
Manufacturer's standards

11.2

General guidelines

11.2.1

Heat exchangers for engine cooling


The heat exchangers offered are suitable for non-aggressive raw water (fresh
water). If aggressive raw water is used (e.g. brackish water, industrial waste
water) we are unable to accept any warranty for the heat exchangers, pumps,
pipes and other units in contact with such water.
For the first filling of the system, water used in the cooling system has to meet
the requirements listed in chapter 9. The treatment, kind and amount of added
chemicals are related to the water quality available at site.
The water shall be available at the plant premises with a pressure of 4-6 bar.

11.2.2

Painting of the supplied equipment


Auxiliary equipment is delivered in the original colour as supplied by the sub
supplier, if not specified in this document otherwise.

11.2.3

Miscellaneous
Anything not specifically mentioned in the quoted scope is not included.
Minor changes due to technical development, design and output are reserved.

11.2.4

Required information from the customer


In case of order the customer shall supply to MAN Diesel & Turbo the following
documents and information in due time:
Actual site plan and arrangement drawing showing the exact location and
dimension of the area of the power plant and the neighbouring installations
Main wind directions and seismic activities to be considered
Minimum load bearing capacity of power plant subsoil or soil investigation
report
List of electrical consumers to be provided locally by customer
Sample of heavy fuel oil, raw water

Water
treatment,
mains water
supply

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
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Nababganj Power Plant - 55MW


Section 11 - Standards, Guidelines and Drawings

11.3
11.3.1

11.4

Drawings
Drawing of generating set
Drawing: 11745001770_01_A_Genset Drawing 18V4860TS (Rev. A, Dtd.
06.06.11)
Division of Works
5301959-01-B001 DOW Rev000

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Nababganj Power Plant - 55MW


Section 12 - General information

12
12.1

General information
List of sub suppliers
This list includes a selection of the major equipment components and the
respective sub-suppliers selected and approved by MAN Diesel & Turbo.
Further sub-suppliers may be considered after MAN Diesel & Turbo quality
auditing. In any case MAN Diesel & Turbo reserves the right to select the subsupplier at its discretion.

12.1.1

Generating set
Alternator
ABB, Hyundai, Indar, WEG GermanyCummins, Jeumont
Flexible coupling
VULKAN, Centa
Anti vibration mountings
GERB

12.1.2

Lube oil system


Lube oil module
Lube oil flow rate measuring device
Lube oil separator module
Lube oil transfer pump

12.1.3

12.1.4

12.1.5

Cooling water system


Cooling water pre-heater set
Nozzle cooling water module
Radiator cooling system

Fuel oil system


Diesel fuel oil supply pumps
Heavy fuel oil supply pumps
Heavy fuel oil filter module
Diesel oil filter module
Fuel oil separator module
Leakage oil module

Intake air system


Intake air filter unit

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Auramarine, MAS, Alfa Laval,


GEA Westfalia Separator
Endress & Hauser,
Bopp & Reuther
GEA Westfalia Separator, Alfa Laval
Kracht, Rickmeier

ELWA, Midland Combustion


ELWA
Ecodyne, Alfa Laval Vantaa, Thremofin,
Friterm, GEA Erg-Spirale

KRAL, Imo Pump, LEISTRITZ


KRAL, Imo Pump, LEISTRITZ
Alfa Laval Moatti, BOLL & KIRCH, Filtrex
Alfa Laval Moatti, BOLL & KIRCH, Filtrex
Alfa Laval, GEA Westfalia Separator
Hydac, MAS

AAF International, GEA Delbag, ALS

Date 2012-02-21
Page 51 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

12.1.6

12.1.7

12.1.8

12.2

Compressed air system


Starting air compressor
Starting air receiver
Compressor unit for working air

Sauer & Sohn, Neuenheuser, Kaeser


Rmer
Sauer & Sohn, Neuenheuser, Kaeser

Exhaust gas system


Expansion joint for exhaust gas

KE-Burgmann, Stenflex, Witzenmann

Electrical equipment
Engine and alternator control system

Kuhse, Woodward,
Siemens Pakistan, Natus

References
MAN Diesel & Turbo can look back on nearly
120 years of experience in the manufacture and
operation of Diesel engines. It was at MAN in
Augsburg that, between 1893 and 1897, Rudolf
Diesel's groundbreaking idea, the Diesel engine,
was developed to the point where it was ready
to go into service.
MAN Diesel built the worlds first large scale Diesel
power station in Kiev in 1904 and supplied engines
for the first ocean-going Diesel engine-powered
vessel in 1912.
To date MAN Diesel &Turbo SE has installed approx.
26,900 medium speed engines with an output of
approx. 56,000 MW all over the world.

References of engines from the current programme:


Engine type

No. of engines

Total Power

16/24

2,525

1,486 MW

21/31

1,454

2,074 MW

27/38

2,176

5,144 MW

28/32

5,106

8,201 MW

28/33

52

32/40

3,006

400 MW
13,572 MW

32/44CR

44

260 MW

48/60

784

9,411 MW

51/60DF / 51/60G

19

254 MW

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5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 52 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

58/64

462

4,903 MW

Others

11,231

10,283 MW

Please find below a reference list of selected power plant installations.

No. x Engine

Total
Power

Customer

Country

VINLEC Extension

St. Vincent

Guadeloupe

France

Breitener Gas Conversion

Brazil

Stelco IV

Maldives

2 x 18V32/40 18.0 MW

Yanbu Cement Extension

Saudi Arabia

6 x 12V48/60 75.6 MW

Komsilga

Burkina-Faso

1 x 18V48/60 18.9 MW

Extension Owen Springs


Karadeniz Power Ship #1

Australia
Turkey

EDF Extension

Martinique

AL TAKAMOL

Egypt

5 x 18V32/40CD 45.0 MW

PLC MEZHREGIONENERGO

Russia

1x 18V32/40PGI

ENDESA GENERACION

Spain

HUB POWER

Pakistan

11 x 18V48/60 207.9 MW

ELECTRAWINDS

Belgium

2 x 18V32/40 18.0 MW

Endesa

Spain

CENTRAIS ELETRICAS

Brazil

CENTRAIS ELETRICAS

Brazil

38x 18V32/40 342.0 MW

OKINAWA Electric

Japan

1 x 18V48/60 18.9 MW

Asian Colour Coated Ispat Ltd.

India

Honda Siel Cars


Asian Colour Coated Ispat Ltd.

2 x 9L32/40

9.0 MW

9 x 18V48/60 170.1 MW
1 x 18V51/60DF 17.5 MW

1 x 12V51/60DF 11.7 MW
6 x 18V51/60DF 149.4 MW
3 x 14V48/60
6 x 18V48/60 113.4 MW
8.1 MW

1 x 12V48/60 12.6 MW

1 x 9L21/31

1.9 MW

2 x 9L32/40

9.0 MW

2 x 16V28/32S

7.5 MW

India

1 x 8L27/38

2.6 MW

India

1 x 18V28/32S

4.2 MW

Grasim Industries

India

1 x 8L27/38

2.6 MW

POWER AND WATER

Australia

Ambatovy

Madagascar

3 x 7L27/38

6.7 MW

STX Dalian

South Korea

2 x 6L27/38

4.0 MW

STX Dalian

South Korea

2 x 8L27/38

5.3 MW

Electric Power Develop. Co Ltd

Japan

VOESTALPINE Stahl

Austria

2 x 12V32/40DF

9.6 MW

National Electricty Corporation

Sudan

2 x 18V28/32S

8.5 MW

EDA, Electricidade dos Acores

Portugal

1 x 7L32/40

3.5 MW

CARIBBEAN UTILITIES

Cayman Is.

UNE Cuba Energoimport

Cuba

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

2 x 12V51/60DF 24.0 MW

3 x 18PA 6 15.9 MW

1 x 14V48/60 14.7 MW
11 x 9L28/32H 20.8 MW

Date 2012-02-21
Page 53 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

No. x Engine

Total
Power

Customer

Country

UNE Cuba Energoimport

Cuba

1 x 18V28/32S

UNE Cuba Energoimport

Cuba

7 x 18V28/32S 28.4 MW

UNE Cuba Energoimport

Cuba

7 x 18V28/32S 28.4 MW

UNE Cuba Energoimport

Cuba

12 x 18V28/32S 48.6 MW

BEC Cat Island

Bahamas

BEC Hatchet Bay

Bahamas

PPC - Grecce Islands

Greece

Grnlands Energiforsyning

Greenland

Grand Bahama Power

Bahamas

EDF Port Est, La Reunion

France

EDA, Electricidade dos Acores

Portugal

EDF Bellefontaine, Martinique

France

Grnlands Energiforsyning

Greenland

1x18V28/32S

4.2 MW

Geoterm

El Salvador

4 x 18V48/60

75.6 MW

Electrawinds, Brugge

Belgium

2 x 18V48/60

37.8 MW

Belco

Bahamas

4 x 12V48/60

50.4 MW

Energetica Camacari Muricy

Brazil

8 x 18V48/60 151.2 MW

Atlas Power

Pakistan

BEC Bimini

Bahamas

BEC Cat Island

Bahamas

Tortola

Brit. Virgin
Island

BLM-Suez

Panama

Barcelona Airport

Spain

IGI Termoindustriale

Italy

OXON Termoindustriale

2 x 9L28/32H

4.1 MW

3.8 MW

4 x 18V28/32S 16.2 MW
1 x 12V32/40

6.0 MW

1 x 18V28/32S

4.2 MW

1 x 18V48/60 18.9 MW
9x18V48/60 170.1 MW
2x5L21/31

2.0 MW

6x18V48/60 113.4 MW

11 x 18V48/60 213.6 MW
2 x 9L32/40

9.0 MW

2 x 9L32/40

9.0 MW

4 x 18V32/40

36.0 MW

10 x 18V32/40

90.0 MW

5 x 18V32/40DF

36.0 MW

1 x 18V32/40

9.0 MW

Italy

1 x 18V32/40

9.0 MW

Isolux

Ecuador

2 x 12V32/40

12.0 MW

Milos

Greece

2 x 12V32/40

12.0 MW

PAMPA Energia S.A.

Argentina

2 x 18V32/40

16.2 MW

ADANAC Ruby Creek

USA

4 x 18V32/40

36.0 MW

Ingemas

Senegal

4 x 18V32/40

36.0 MW

Surimane Phase 3
N.V.Energiebedrijven Suriname

Suriname

1 x 18V32/40

9.0 MW

Ceuta
ENDESA

Spain

3 x 12V48/60

37.8 MW

Mosoblenergogas

Russian
Federation

2 x 16.0 MW
18V32/40PGI

Melilla
ENDESA

Spain

3 x 12V48/60

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

37.8 MW

Date 2012-02-21
Page 54 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

Customer

Country

Arabian Cement Co. Ltd.

Saudi
Arabia

INCA
Santo Domingo

Dominican
Republic

UNE 2
Energoimport de la Habanna

Cuba

UNE 3
Energoimport de la Habanna

Cuba

SONABEL
La Soc. Nat. dElectricit

No. x Engine

Total
Power

3 x 18V48/60

56.7 MW

2 x 9L32/40

9.0 MW

7 x 18V48/60 132.2 MW
1 x 18V32/40DF

6.9 MW

Burkina
Faso

1 x 18V48/60

18.9 MW

Chekka
Holcim Leban S.A.L.

Lebanon

1 x 18V48/60

18.9 MW

Sepcol
Southern Electric Power Co.Ltd.

Pakistan

1 x 18V48/60
5 x 18PC4.2

128 MW

Ibiza
Spain
ENDESA for Gas y Electricidad S.A.

4 x 18V48/60

75.6 MW

Sharourah
Al-Saleem / Saudi Electric Comp.

Saudi
Arabia

3 x 12V48/60
2 x 12V48/60

63.0 MW

Fortune Electric, Taipei


Taiwan Power Co.

Taiwan

4 x 9L32/40

18.0 MW

NATCO
Public Electric Comp.

Yemen

1 x 16V32/40
1 x 12V32/40

20.0 MW

Surimane
N.V.Energiebedrijven Suriname

Suriname

2 x 18V32/40

17.2 MW

Shuaiba
ABB / Public Authority for Industry

Kuwait

1 x 9L48/60

9.4 MW

GECSA
Genedora Electrica S.A.

Guatemala

2 x 18V32/40 19.0 MW

White Nil Petroleum Operating


Company

Sudan

5 x 18V32/40

54.0 MW

Choloma IIII
Energia Renovables S.A.

Honduras

14 x 18V48/60

265 MW

Los Guinchos, Las Palmas


ENDESA for UNELCO

Spain

4 x 12V48/60

50.4 MW

Las Salinas, Fuerteventura


ENDESA for UNELCO

Spain

3 x 18V48/60

56.7 MW

Punta Grande, Lanzarote


ENDESA for UNELCO

Spain

5 x 18V48/60

94.5 MW

Weipa
Comalco Aluminium Ltd.

Australia

6 x 9L32/40

27.0 MW

Pico / Belo Jardim


Electricidade dos Acores

Portugal

1 x 7L32/40
2 x 12V48/60
4 x 9L40/54

58.5 MW

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 55 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

Country

Grand Bahama
Grand Bahama Power Comp.

Grand
Bahama

1 x 18V48/60

18.9 MW

Caracol Knits
Ingemas, Gijon

Honduras

1 x 12V48/60

12.6 MW

St. Vincent
Vinlec

St. Vincent

2 x 9L32/40

9.0 MW

Pembroke / Bermunda
Bermuda Electric Light Comp. Ltd.

Bermuda

2 x 14V48/60

29.4 MW

Benue Cement Company (BCC)

Nigeria

5 x 18V32/40

45.0 MW

Comp. des Ptroles

Libya

2 x 18V32/40

17.0 MW

Pedregal Power Company

Panama

3 x 18V48/60

56.7 MW

Caribbean Utilities Comp. Ltd.


Grand Cayman

Cayman
Islands

2 x 14V48/60
1 x 12V48/60

38.0 MW

Aqualectra, Curacao

Netherlands
Antilles

4 x 18V32/40

34.5 MW

China National Offshore Oil Corp.


(CNOOC)

China PR

5 x 16V32/40
5 x 16V32/40

76.8 MW

Poplar Bluff / Mississippi

USA

3 x 18V32/40DF

21.0 MW

Consorcio Breitener
for Forteleza Power Station

Brasil

8 x 18V48/60
2 x 16V32/40

167 MW

Peng Hu
TATUNG Co.

Taiwan

8 x 9L58/64
4 x 12RK270

125 MW

Habas Kasimpasa

Turkey

3 x 18V48/60

57.0 MW

Esemboga
Ankara Enerji Uretim A.S.

Turkey

7 x 16V32/40

53.8 MW

Mineracao Rio Do Norte S.A.

Brasil

5 x 9L48/60

47.0 MW

Dohuk, Erbil, Sulaimaniyah


UNDP for Local Electricity Authority,

Iraq

3 plants with 92.0 MW


4 x 16V32/40

Union Fenosa S.A.

Dominican
Republic

5 x 18V48/60

94.5 MW

Power Barge Esperanza


Puerto Quetzal Power Ltd.

Guatemala

7 x 18V48/60

132 MW

Nouakchott
SONELEC

Mauretania

2 x 9L48/60
4 x 52/55B

54.0 MW

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

No. x Engine

Total
Power

Customer

Date 2012-02-21
Page 56 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

12.3

Leaflets and brochures


Following brochures are available on our homepage in electronic format or can
be handed out as hardcopy upon your request.
Stationary Engine
Programme 2011
MAN Diesel & Turbo power plants are located in all
regions of the world in deserts, on pack-ice, at
low altitude or in high mountain regions. Whether
located in an area with a climate of dry heat,
tropical air humidity, permanent frost or extreme
temperature fluctuations, our power plants always
provide reliable energy.
Our power plants are able to be operated on
various kinds of fuels with highest flexibility and
economy.

Powering the World


Brochure with general information about the
MAN AG Group of companies and specially
MAN Diesel SE, its history, product portfolio and
worldwide services.
MAN Diesel, the "birthplace of the Diesel
engine", is one of the world's leading suppliers of
large-bore Diesel engines for marine application,
energy production, railways and heavy duty
vehicles. In addition, MAN Diesel & Turbo also
build turnkey power stations and complete
propulsion systems for ships.

Power Plants
Energy wherever you need it.
MAN Diesel & Turbo is one of the worlds leading
suppliers of land-based and floating power plants
based on Diesel and gas engines. Over the last
century we have built thousands of Diesel power
plants worldwide. The experience we have gained
and the technology we have developed over that
time enables our specialists to tailor power plants
to the individual needs of customers all over the
world.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 57 of 58

Nababganj Power Plant - 55MW


Section 12 - General information

18V48/60TS
Two-stage turbocharged diesel engine
Brief description of the MAN Diesel & Turbo engine
type 18V48/60TS with technology information and
technical details as well as engine dimensions.
The first choice when it comes to economy and
ecology. With a power output range of 18,900 kW
to 21,600 kW, this reliable, high-output engine is
the four-stroke heart of medium and large diesel
power plants the world over.
A true prime mover.

TCA
The New Turbocharger Generation
MAN Diesel & Turbo has more than 60 years
unprecedented experience of producing
turbochargers with plain bearings and uncooled hot
gas casings.
The new series of TCA turbochargers are available
in 2 stroke and 4 stroke versions for diesel, dual fuel
and gas engines. They have been developed to
provide a robust and reliable platform for engine
applications ranging from 2,500 kW up to
35,400 kW output per turbocharger.

Courses 2011
MAN PrimeServ Academies
Customised training programmes from basic Diesel
engine maintenance to complete power plant
operation.
We offer training modules for your Plant Managers,
Maintenance Personnel, Operators and Control &
Instrumentation staff.
In-factory and at-site courses for increased
productivity and enhanced quality.

Our Reference 5301959-01-B001


5301959-01-B001 Technical specification Rev000

Date 2012-02-21
Page 58 of 58

Annexure 2(b)
Co-generation Engine Specification

RUPALI ENGINEERING & TRADERS


LIMITED

TECHNO-COMMERCIAL OFFER
COGENERATION 2.35MW
28.05.2013

(3X18V48/60TS MAN POWER PLANT)

MAGNUS POWER PRIVATE LIMITED BANGALORE INDIA

TABLE OF CONTENTS
COGENERATION POWER PLANT
1
2
3
4
5
6

GENERAL
SCOPE OF SUPPLY
TECHNICAL SPECIFICATIONS OF BOILER
TECHNICAL SPECIFICATIONS OF TURBINE GENSET
PRICE SCHEDULE
GENERAL TERMS & CONDITIONS

1- GENERAL
The Cogeneration Power Plant includes a well designed:

One (3) nos. of ALFA LAVAL (AALBORG)WHRB with all other auxiliaries.
One (3) nos.of DAMPER, Electrically operated gas diverter damper.
One(1) no. of TRIVENI Turbine Generator Set with Steam turbine, Condensing System
and AC Generator with all other auxiliaries.
Sl No.

Description

Parameters

Plant Location

Bangladesh

Details of each engine

Engine Capacity (MWm) MAN-18V48/60 TS

18.9

Fuel

HFO

Exhaust Gas Flow (Kg/hr)

Exhaust Gas Temperature (Deg C)

Exhaust Gas Composition (V/V%)

122000
300

CO2

5.50

O2

12.10

H2O

7.50

SOX

0.08

NOX

0.12

CO

0.01

N2

75

TECHNICAL SPECIFICATIONS OF COGENERATION POWER PLANT


Sl No.

Description

Unit

Qty

Kg/hr
Deg.C

122000
300

3
Natural circ
3
YES
YES
YES
NO
Modulating
9 PCS
DN 1600

Forced cir. LP evaporator


with cir. pumps, 2 pcs

1
2
3
A
B
C
D
E
F
G
H
I
J
4
A
B
C
D
E
F
G
H

Exhaust gas flow in HRU (for one engine)


Exhaust gas temperature HRU (for one engine)
GENERAL INPUT DATA
Number of boilers
HP-evaporator
Number of steam drums
Superheater
HP economizer
LP evaporator/preheater
Hot water section
By pass
Automatic rake soot blowers
Exhaust gas pipe diameter
THERMAL INPUT DATA
Exhaust gas flow/engine
Exhaust gas temperature IN
Exhaust gas temperature OUT, ECO
Exhaust gas temperature OUT, LP
Temperature in feed water tank
Condensate temperature
Condensate return %
Make-up water temperature

HP evaporating pressure

16.1 bar(a)

Steam pressure after superheater

16.0 bar (a)

5
A
B
C
D

OUTPUT DATA (With clean heating surface) per


boiler
Capacity
HP
Steam flow per boiler
HP
Steam Temperature
HP
Exhaust gas pressure drop (clean)

4048 Kw
6071 kg/h
2800C
1130 Pa

6
A
B
C
D
E

PRELIMINARY DIMENSIONS( BOILER)


Length
Width
Total height (incl. drum)
Total water volume (boiler/drum/pipes)
Max weight (full of water)

Power Generation Equipment

33.9 kg/s
300.0 0C
204.6 0C
194.9 0C
135 0C
80.0 0C
97.0 %
30

122 000 kg/h

NOTE:
F. W. Tank heating
included
Boiler steam flow data is
Stated after deduction of
Heating steam

5460 mm
2690 mm
11410 mm
4.1/3.8/1.m3
69299 kg

Turbine steam turbine- multistage condensing


A

Gross Electric Power Generation

kWe

2350

Power generation Voltage/Frequency

kV/Hz

11/50

2 SCOPEOF SUPPLY
-IncludedinMPPLScope
ItemDescription

X-ExcludedfromMPPLScope
Fabrication
Basic
Detailed
Sup
Supply
Site &
Engineering Engineering
Com
Erection

VILWORKANDRELATEDACTIVITIES
asteHeatRecoveryBoilers
ilerfeedwaterPumps
cessories&AuxiliariesPackageforWasteHeatRecoveryBoiler
eamTurbinePackage
aterCooledCondenserPackage
ndscaping,Roadandrelatedactivities
ilerWaterTreatmentPlant&ETP
ow downpit,NeutralizationPit,EarthingPit
uck ableroadup tofoundation

X
X
X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X

ASTEHEATRECOVERYBOILER PACKAGE
ainHeatRecoveryBoiler- 3 Nos
essurePart
ilerCasing
uctureandSupport
aterCooledCondenserPackage
undationBolts
otblowersfortubecleaning
struments,MountingsandControlsof WHRB
haustandbypassgasDivertervalveforgasisolation
rewAirCompressorforInstrumentair
aterTreatment PlantforBoiler feedand cooling towermake-up.
mplecoolers
owdownsystemforWHRB
aerationsystemstankandChemicaldosing
xiliariesandaccessoriesofWHRB

X
X

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

HAUSTGASDUCTINGAND SUPPORTING STRUCTURE PACKAGE


ctingfromHeatSourcetoDiverterdamper
ctingfromDampertoWHRBInlet
ctingfromWHRBOutlettoExistingDuct
pportingstructureforDucting

X
X
X
X

EAMTURBINEANDAUXILIARIES PACKAGE

eamTurbinewithGenerator
aterCooledCondenserPackage
olingTowerPackageforMainandAuxiliary
ushingLubricantsOilandfirstfillofchemical

ECTRICAL&INSTRUMENTATION PACKAGE
steamandwatercontrolvalveassemblies
strumentation and control cabling for Wasteheat driven power plant
thin battery limit.
rbine and Generator Protection Panels (NGR, Relay metering control &
nch panel,Turbine control panel, AVR panel).
ectricalinspectorateclearancesifany
earances/approvalsstatutorybodyfromproposedSEBorPoweranyotherPlant.
cumentation support for the inspection /
proval,statutoryapprovalsetc.ofelectricalinspectorate
art-up,GenerationCumPower
acuationsystem:kVPowerPlantSwitchgearSystemwithinbattery limit
Cable
cablewithinbatterylimit.
VSwitchgearSystemforpowerplantwithinbatterylimit
KVIndoorMVSwitchgearSystem
Vcableandcabletraywithinbatterylimit
tterybackupforMVswitch gearchargersystem&EOP(1starter)

PINGWITHSUPPORTINGSTRUCTURE PACKAGE
eam&FeedWaterPiping
ndensatePiping
strumentair,DrainandVentPiping
olingWater&CondensatePiping
pansionLoops/BellowsinabovePiping
pportingstructureforabovePiping
SULATIONANDCLADDINGPACKAGE
sulationandCladdingforWHRBPackage
cludingmainWasteheatrecoveryboilers,
Atank,Blowdowntank,Dampers,Ductotheraccessoriesinboiler package
sulationandCladdingforDuctingPackage
sulationandCladdingforPipingPackage
sulationGeneratorandsetPackageCladdingforTurbine&

X
X
X
X

X
X

X
X

X
X

SCOPE EXCLUDED
Sl. No.
B
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION
Cold start up power
Water treatment plant for boiler water and cooling water topping up
Required land, landscaping, road and related activities
Effluent treatment Plant
Statutory approvals
Freight & Transit Insurance
Street Illumination system and Illumination outside battery limit of Proposed power plant
Pollution and Factory approval
Any Electrical system analysis and study
EPABX System
Emergency shutdown system

3 TECHNICALSPECIFICATIONS OF HEAT RECOVERY BOILER ALFA LAVAL


1.) EXHAUST GAS BOILER, AV-6N / NATURAL CIRCULATION 3 No
Construction: AV-6N exhaust gas boiler is a water tube exhaust gas boiler, optimized for
heat recovery from diesel engine exhaust gas. The boiler generates superheated steam for
steam turbine application.
The boiler consists of following heating sections: Super heater, evaporator and economizer.
The exhaust gas inlet is in the upper part and the outlet in the lower part of the boiler, i.e.
exhaust gas flows downwards.
The extended heat transfer surfaces consist of horizontal plain steel tubes equipped with
steel fins. These water tubes are connected to inlet and out manifold pipes. The tubes are
twin tube construction of material P235GH/EN10217-2 or equal and the size of the tube is
38mm. The minimum wall thickness is 3mm.
Special attention is paid to the flexible construction of the heating surface where the tubes
can freely expand to minimize thermal stresses.
The heat surface is surrounded with welded steel cover casing, stiffened by steel bars and
connected to upper/lower exhaust gas chambers. Material of steel construction is S235JRG2
or equal.
Soot blowers: The boiler is equipped with three (3) automatic rake soot blowers. The soot
blowers are operated one at a time when the engine is running. Steam soot blowing is used
to prolong the interval of manual water washing.
Water washing: The off-service manual water washing is very important and recommended
to be made as minimum during every major engine shut-down and can be executed through
the service hatches.

The washing water drain connection at boiler bottom is equipped with a camlock system.
The connection is normally closed with a cap. During the water washing, the connection is
locked to a plastic drain hose (common hose included).
System Connections: The individual AV-6N exhaust gas boiler is to be connected to its own
steam drum and to the common feed water tank via feed water piping. The individual AV6N exhaust gas boiler is also to be connected to a common steam line.
Operational description (individual boiler): The feed water is pumped with feed water
pumps through the economizer into the steam drum. The water recirculation between the
steam drum and the evaporator is maintained by natural circulation. The evaporated
(saturated) steam is separated in the steam drum and directed through the super heater
into the steam header and further as the combined superheated steam flow to steam
turbine.
Note: Feed water tank heating is included; boiler steam flow data is stated after deduction
of heating steam.
The stated values are valid with clean heating surfaces. Aalborg Industries guarantees the
indicated steam flow at the design point when the boiler is operated and maintained clean
according to the AI instructions and O & M manuals.
When defining the steam capacity the exhaust gas mass flow of the engine is determined by
calculations, meaning and no separate flow-measuring device is included in the scope of
supply.
The exhaust gas boiler is delivered as a complete construction with loose packed insulation
material including the following items;
Exhaust gas chambers with flanged connections
Top casing prepared for site-installation of stem drum
Flanged inlet/outlet connections for water side
Insulation flat bar supports
Maintenance/service hatches
Supporting and lifting lugs
Water washing cam lock drain with common plastic hose of 20m*)
Valves and fittings (closing valves, thermometers, pressure gauges pressure
difference gauge) with bolts, nuts, gaskets and counter-flanges*)
Soot blowers*)
Prefabricated boiler pipes with site allowance; rises, down comer, economizer outlet
and superheating inlet pipe*)
Exhaust gas counter flanges (incl. gasket, bolts and nuts*))
Feed water control as unit*)

2.) STEAM DRUM 3 No


Individual steam drums to be connected to individual exhaust gas boilers.
Construction: UNEXTM HK is an all-welded steam drum consisting of steel cylinder and dished
ends. Material of steel construction is P265GH/EN10028-2 or equal.
Note: Steam turbine pressure fluctuation range should be checked against the above design
pressure and when presetting the safety valve opening pressure.
The steel construction of HK steam drum is delivered as a complete unit with insulation
including the following items
o Stands for installation
o Fittings with flanged connections
o Man hole for maintenance/service
o Lifting lugs
o Valves and fittings according to the following instrumentation list *)
Steam outlet closing valve
Safety valve (with a spare connection)
level gauge
automatic FW control with valves and water level alarms
manual bottom blow down/drain
manual scum blow out valve
sample cooler
venting
pressure gauge
pressure switch for high pressure alarm
pressure transmitter for bypass damper control
3.) STEAM HEADER 1 No
The steam header is used to collect steam from individual exhaust gas boiler for further
distribution to steam turbine.

Steam from exhaust gas boilers (1) with closing valves


Stem from oil fired boiler, with closing valve
Steam to consumers, with closing valve
Steam to consumers, with closing valve
Steam to feed water tank, with closing valve
Pressure gauge with cock
Pressure transmitter with cock for bypass damper control
Condensate/Drain with steam trap and closing valves

The steam header is delivered without insulation. Unused standard connections are
equipped with blind flanges. All valves and instruments are delivered loose.

Manual blow-out valves for the incoming boiler steam lines are included as loose.
4.) AUXILIARY CONTAINER, AIC-20/COMMON SYSTEM 1 No
The containerized modular includes ready installed components as specified in items (ITEM
3) and necessary fittings including all piping and cabling work inside a 40 container (not
classified)
Note: Feed water tank is to be site-installed on top of the container on a separate
supporting. The tank foundation supporting and service platform. Connecting pipes
between the feed water tank and container (prefabricated with work allowance) are
supplied loose and will be installed at site by the KPPGL. Chimney (height 10m without
insulation) and foundation anchoring for chimney are included as loose supply.
Hot surfaces inside the container are insulated and covered with aluminum plates. Valves
are insulated or contact protected, if they are close to general walkways or service areas.
The container is equipped with one double door at the other end, one service door at the
side and ventilation hatch with fan.
5.1 FEED WATER PUMPS 2 Nos
The delivery consists of 2 feed water pumps; both sufficient for pumping feed water for 3
exhaust gas boilers at nominal capacity. The both pumps have 100% of needed capacity.
The other pump is a spare.
The indication of the emergency low level of feed water tank is used to stop the feed water
pumps
Technical data
Type
Capacity
Motor
Shaft sealing

Vertical centrifugal pump


10.2 m3/h ; 13 bar
7kWe
Mechanical

5.2) Local PLC control system, Siemens TCP/IP 1 No


The delivery includes the necessary control system with all required components for
controlling and operating the steam heat recovery system according to Aalborg Industries
standard.
The following alarms are available for remote monitoring
Common alarm
Pressure alarm high
Steam pressure at the common steam header

Steam temperature at the common steam header


Bypass damper position

The control system consists of one common control panel with Siemens MP277 &WInAC MP
2007 control logic.
5.4.1) Drum water regulating and control system
The boiler water regulating and control system is based on direct measurement of the water
level by conductivity and capacitance method. The system consists of two electrodes and
electric controllers.
This system controls feed water control valves (open/close) and gives an alarm signal of high
and low water level as well as emergency low water level alarm.
5.4.2) Feed water regulating and control system 1 Set
The feed water tanks regulating and control system is based on direct measurement of the
water level. This system control makeup water value (open/close) and gives an alarm signal
of high and low water level as well as emergency low water level alarm. The emergency low
water level of the feed water tank stops also the feed water pumps.
5.4.3) Starter for feed water pump
The starter includes the following components:

Protection switches
Contractors
Main switch
Operation switches for pumps:
Indication lamps
- Pump 1 is operating
- Pump 2 is operating
- Pump failure

5.4.4) Capacity control of the exhaust gas boilers


Stem production of the boiler is controlled according to pressure in the system
Normal pressure range of the system is between 13,5 16 bar(a)
The capacity of the exhaust gas boiler is controlled by PID-controller which gets the pressure
signal from the pressure transmitter installed to the respective steam drum. PID-controller
gives control signal to the modulating by pass damper. Set point of the PIC-controller is 16
bar(a)
6.) Chemical dosing unit 1 No

This unit is mean for adding chemicals into the feed water system for mild after-treatment
and oxygen removal.
The system includes following:
Dosing pump
Suction filter
Dosing nozzle
Plastic tank of 100 liters
Note: A steam turbine application sets strict requirement for the water quality and
therefore the combined cycle plants usually are equipped with special treatment plants for
securing high quality water.

7.)BLOWDOWN TANK, BDT-150 1 Nos


Blow out procedures must be executed periodically for any type of steam boiler to remove
concentrations of solids, which would otherwise buildup in the boiler water.
The blow down tank is designed to safety handle those hot discharge with a self-acting
temperature control of cooling water.

8.) PRESSURIZED FEED WATER TANK, PSVS-16 1 No


The feed water tank is used to secure the feed water reserve for the exhaust gas boiler
system. Water in the tank consists of condensate and fresh make-up water, which are
mixed in tank together with boiler water light-adjustment chemicals
Construction

NEX PSVS is an all-welded horizontal feed water tank consisting of


horizontal steel cylinder and dished ends. Material of steel
construction is P265GH/ EN10028-2 or equal
Condensate line is connected to the tank and added make-up water
to the stainless steel deaerator which is installed on the top of feed
water tank.

Temperature control Feed water is kept hot in order to reduce the amount of oxygen in
boiler water.
The temperature in the feed water tank is maintained by an
automatic temperature control value. This is backup system activated
by low set point of feed water tank temperature whilst the exhaust
gas preheating is the primary heating method. As the heat transfer
from the exhaust gas preheater is proportionally to temperature of
the water flow, increasing temperature will automatically be
controlled by respectively reduced heal transfer to feed water tanks
circuit.

Technical data

Total volume
Operation temperature
Operation pressure
Design pressure

16 m
134 C
3 bar (a)
4 bar(g)

The steel Construction for PSVS-pressurized feed water tank is


delivered as a complete unit with insulation including the following
items.

Stands for installation


Fittings with flanged connections
Man hole or maintenance /service
Lifting lugs
Deaerator
Valves and fittings according to the following instrumentation
list*)
- Feed water outlet closing valve
- Safety valve
- Automatic makeup water regulating and control with
valves and water level alarms(integrated level
indicator)
- Manual bottom blow down/drain
- Manual scum blow out valve
- Sample cooler
- Venting
- Thermometer
- Automatic stem injection control for maintaining the
set temperature.

9.ELECTRICALLY OPERATED GAS DIVERTER DAMPER

Medium
Flow rate
Temperature
Pressure
Damper size
Blade type
Sealing efficiency
Operation
Duty

:
:
:
:
:
:
:
:
:

Exhaust gas
129900 Kg/hr
400C
300mmWC
1650 sq.mm
Single type
99.5% on C/s area
Electrical
Modulating

4 TECHNICALSPECIFICATIONS OF TURBINE GENERATOR SET (TREVENI)


1.)

STEAM TURBINE

Design:
Type

Casing split
Rotor type

:
:

Shaft seal
No. of governing valves

:
:

Bearing support
Rated power

:
:

Multistage, impulse, nozzle governed


Condensing
Horizontal
Solidly forged & machined rotor with integral
disks.
Labyrinth
Three (Inlet)
One/(Extraction)
Double pedestal
2350 KW

:
:
:

5.5 kg/cmg
1.5 KG/Cmg
Servo prime ISO VG-46 /57 /68

:
:
:
:

5100 L
3200 L (integral)
5 minutes
Carbon steel

Carbon steel

SS 304

Carbon Steel

- Main oil pump:


Type
Operating speed
Capacity
Driver
Material of body
Material of end cover
Material of drive gear

:
:
:
:
:
:
:

Gear (positive displacement) / Screw


1500 rpm
-/minute
Gearbox low speed shaft
CI
CI
EN 36 /EN 40

- Auxiliary oil pump:


Type
Operating speed

:
:

Gear (positive displacement)/screw


1500 rpm

Oil System
- Oil:
Governing oil pressure
Lube oil pressure
Oil type
Oil quantity for initial fill
And flushing
Oil reservoir capacity
Retention time
Material of oil reservoir
Material of oil piping from
Pumps to filter
Material of oil piping from
Filters to bearings
Material of oil piping from
Bearing to reservoir

Capacity
Drive
Material of body
Material of end Cover
Material of drive gear

:
:
:
:
:

350 L / Minute
AC motor
CI
CI
EN 36 EN 40

- Emergency oil pump


Type
Operating speed
Capacity
Driver
Material of body
Material of end cover
Material of drive gear

:
:
:
:
:
:
:

Gear (Positive displacement)


1500 rpm
48 L / minute
DC motor
CI
CI
EN36 /EN40

- Oil cooler:
Design code
Type
Oil inlet temperature
Oil outlet temperature
Plate material
Oil flow capacity
Mounting

:
:
:
:
:
:
:

HEI/TEMA
Plate Hear Exchanger
60 C
46 C
SA 240 Gr.316
550 Liters /minute
Saddle support

- Lube oil Filter


Element type
Oil flow Capacity
Oil filtration Capacity
Mounting

:
:
:
:

Micro felt
350 liter/minute
10-15 microns
Foot

- Oil Vapor Extractor


Type
Capacity
Driver
Mounting

:
:
:
:

Centrifugal
400m/Hr
AC Motor
Flange

:
:
:

Tilting pad
White metal with steel Babbitt

:
:

Tilting Pad
White metal with steel Babbitt

Bearings:
Journal bearings
Type
Material
Thrust Bearings
Type
Material
Governing system
Governor:

Type
Inputs (critical)
Control range
Control accuracy
Speed droop
Power supply
Accessories

:
:
:
:
:
:
:

Electronic (Wood ward)


2 Speeds from MPU -1 & 2
80 to 110% of rated speed
As per NEMA class D
3 to 6% (Programmable)
110 V DC
2 Magnetic speed pick-ups(MPU)
1 electro-hydraulic actuator

Hydraulic Accumulator
Type
Working fluid
Capacity

:
:
:

Bladder
Pre-charged Nitrogen
20 liters

Governing oil filter


Element type
Oil flow capacity
Oil filtration Capacity

:
:
:

Micro-felt
35 Liters /minute
10-15 microns

Type
S.F.
Accessory

:
:
:

Double helical, single reduction


1.3
Air breather

Flexible element

Flexible element with Shear pins

:
:

Auto disengage
AC Motor

GEARBOX
Design:

COUPLINGS:
High Speed Coupling
Type
Low Speed Coupling
Type
ACCESSORIES
-

Barring gear:
Type
Driver

Gland vent condenser


Type
:
Tube material
:
Shell & end cover material
Tube sheet material
:
Accessory
:
Driver for air blower
:
Noise level
:
2.)

CONDENSING SYSTEM

Shell and tube


Admiralty brass
Carbon Steel
IS-2002
Motor driven centrifugal air blower
AC Motor
90 dB(A)

STEAM SURFACE CONDENSER


Type
:
Capacity
:
Construction
:
Cleanliness factor
:
Hot well retention time :
Tube fixing
:
Tube material
:
Tube sheet material
:
Water box & Shell material
STEAM JET AIR EJECTORS
Suction medium
System elements

:
:

Accessory
:
Time to reach 60% vacuum
With start-up ejector
:
Material of nozzle
:
Material of shell & diffuser
Material of tubes
:
Material of tube sheet :
Material of silencer
:
CONDENSATE EXTRACTION PUMPS
Type
Mounting
Suction pressure
Discharge pressure
Operating speed
Driver
Type of bearings
Type of seal
Type of coupling
Type of lubrication
Material of casing
Material of impeller
Material of shaft
Material of shaft sleeve

:
:
:
:
:
:
:
:
:
:
:
:
:
:

EXPANSION BELLOW
Type
:
Design code
:
Material of bellows element
Material of liner
:

Shell and tube


To suit exhaust flow
Divided water box
0.85
2 minutes
Expanded joints
SS 304 FRW(22 Bwg)
IS-2062 Gr.B
IS-2062 Gr.B

Air / Vapour
Twin Stage, 2 x100% main ejectors
Single stage, 1x 100% start-up ejector
1x100% inter/after condenser
Integral steam strainers
20 minutes
AISI-304
CS
SS-304 ERW
IS-2026
CS

Centrifugal
Horizontal
Same as condenser pressure
80 MWC
2900 RPM
AC motor(415 V, 3 Phase)
Anti friction
Mechanical
Flexible
Oil
CI
CF8M
C45
AISI 316

Rectangular with flow liner


Universal type rectangular expansion joints
SS-304
SS-304

Material of flanges

Is-2062

:
:
:

2350 kW
11KV +/- 10%
50Hz +/- 5%

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

+/- 10%
0.8 (lag)
3 phase,
3 for phase & 3 for neutral
Star
1500 rpm / 4 pole
More than 0.5
45 Deg.C
Brush less
cylindrical
CACW
Horizontal
class F (both rotor and stator)
Class B limits(both rotor and stator)
IP-54(Stator) & IP-54 (Exciter)
Continuous and suitable for parallel operation
To suit driver output
90 dB(A)
To suit HT cables
Is -4722
As per IEEE 519

:
:

Sleeve
Temperature gauge

Lube oil system:


Type
Source

Forced feed
Turbine lube oil system

Air coolers:
Cooling method
Capacity
Cooler tube material
Mounting

:
:
:
:

CACW
2 x 60%
Admiralty brass
Top

3.)

ELECTRICAL

AC GENERATOR
Design:
Rated output
Rated voltage
Rated frequency
Combined variation of
Voltage & frequency
Rated p.f
No. of phases
No. of terminals
Connection
Rated speed /No. of pole
Short circuit ratio
Ambient temperature
Excitation
Rotor
Cooling method
Mounting
Insulation
Temperature rise
Enclosure
Duty
Rotation
Noise level
Terminal box
Reference standard
Harmonic loading
Bearings:
Type
Accessory

Anti Condensation heaters


Type
Power supply

:
:

Resistance heating
230 V, single phase

Water leakage detector


Location
Quantity

:
:

Bottom of cooler
1No. per cooler

:
:
:
:
:

Analog
1 auto +1 manual
+/- 10%
+/- 0.5%
Less than 30 mS

AVR CUM EXCITATION PANEL


Design:
Control type
Control modes
Voltage adj. Range
Regulation
Dead time
Features:
-

Compounding
Auto PF controller
Remote voltage control
Auto- Manual follow-up
Under frequency protection
Field flashing provision

AVR cum excitation panel shall be complete with generator voltmeter, field voltmeter, field
ammeter, PF meter, Auto/Manual selector switch, AC supply & DC supply on /off control
switches, indicating lamps and space heater with thermostat.
TURBINE CONTROL PANEL
Turbine control panel shall house the following:
- Electronic governor with keyed-in operating program
- Condenser hot well level indicator cum controller
- Relay based hard wired turbine safety interlocks and trip logic
- Remote controls comprising of selector switches, ammeters, push buttons &
Indicating lamps for:
AOP motor
EOP motor
CEP-1,2 motor
Barring gear motor
Air blower motor
Vapour extractor motor
- Push buttons for turbine speed raise and lower
- Turbine remote trip/reset push buttons
- Temperature scanner for Monitoring turbine and gearbox bearing temperature

Alarm annunciator for Turbine fault monitoring.

The Panel shall be complete with AC supply & DC supply on / off control switches, indicating
lamps and space heater.
TURBINE GAUGE PANEL
Turbine gauge panel shall house the following gauges:
- Pressure gauges for:
Inlet steam
HP Wheel case
Bleed steam
Exhaust steam
Lube oil
Control oil
- temperature gauges for:
Inlet steam
Bleed steam

5 - PRICE SCHEDULE- THREE BOILER SYSTEM


Sl No.
A

DESCRIPTION

EUROS

BOILER
1] 3nos Exhaust Gas Boiler, AV-6N/Natural circulation
2]3nos Modulating Bypass Damper, DN 1600
3] Steam Drum
4] Steam Header
5] Auxiliary Container, AIC-20/ Common System
6] Blow down Tank, BDT-150
7] Pressurized Feed Water Tank, PSVS-16
8] Condensate Tank C-6
9] Standard Spare parts for Commissioning
10] General Input Data
11] Thermal Input Data
12] Output Data [with clean heating surface]
13]cooling tower

TURBINES
1] Steam Turbine: Multistage, impulse, nozzle
governed condensing 2350 KW.
2] Steam surface Condenser
3] AC Generator 2350kW
4] AVR Cum Excitation Panel
5] Generator Relay Panel
6] Generator Control (Metering Cum Synchronizing)
Panel
7] Neutral Grounding Resistor Panel
8] Turbine Control Panel
9] 11KV panel
Auxiliaries
1.Exhaust Duct and supports/expansion joints
2. Steam & water Pipeline and fittings
3. Cabling
4. Insulation.& cladding
5. support structural frame

Euro 2,975,000.00
(TWO MILLION NINE
SEVENTY FIVE
THOUSAND EUROS
ONLY)

Erection & commissioning:


Erection & Commissioning- supervision - AALBORG
Engineers
Erection & Commissioning supervision - Triveni
Engineers

Euro 160,000.00
E

FRIGHT AND INSURANCE - CHITTGONG PORT (CIF)

[ONE HUNDRED SIXTY


THOUSAND EUROS
ONLY]

6 - TERMS AND CONDITIONS OF SALE


Scope of Supply
The scope of supply is limited to the equipment as listed in our specification

1.0

Scope of Work
The scope of work shall comprise of Works to be performed in accordance with The Scope of
supply provided.

2.0

Contract Price
The Contract Price shall be payable at the time and in the manner provided in PRICE
SCHEDULE.

3.0

Effective Date of the Contract-(EDOC)


The Contract commencement date (CCD) shall be the date of signing of this Contract.
The Effective Date of this Contract (EDOC) shall occur on the fulfillment of each of the
following:
a) Signing of the Contract.
b) Advance Payment and Letter of Credit establishment
c) Approval to proceed with placement of Orders for major equipments.
In case any of these above conditions are not fulfilled within 120 (One hundred and
twenty) days from the date of signing of the Contract, the Parties to this Contract shall
meet and discuss the further course of action.

4.0

Project Execution
This quotation is based on the following assumptions regarding the project execution time
table:
Delivery of equipment : 8 month
Commissioning of the installed equipment : 12 month

5.0

Payment Terms
We have calculated our prices on the assumption that payment will be effected out of an
irrevocable documentary credit, free of charge to us, opened through a Local National bank
confirmed by a German National bank acceptable to us.

The price is payable as follows:


20% down payment with placement of the order.
80% against irrevocable first class bank letter of credit.

6.0

Warranty
The warranty will be valid for 12 months from the date of commissioning or 18 months from
the date of shipment or 8000 working hours for the Power Plant whichever is earlier.
We agree to repair or replace at our option any defective part in the equipment of our own
manufacture, where defects develop under use and arise solely from faulty material or
workmanship, and provided that the equipment is used as per our recommended operating
and maintenance procedures.
In the case of goods not of our manufacture, you are entitled to the benefits of the warranty
given to us in respect thereof, and our liability in respect of such goods is limited to the
warranty given by the respective manufacturer.
The defective parts replaced by us shall become our property. The replacements, if any will
be delivered on the same basis as the main equipment. W shall not be liable for any
consequential damage or loss incurred during warranty claims.
The provisions contained in this clause are not applicable
a. In case of normal wear and tear
b. In case of damage due to negligence or improper handling or repairs/alterations carried out
without our approval or due to damage by any cause beyond our control.
c. If the purchaser has not notified us in writing within a week from the occurrence of any
defect.
d. If the DG set is run after raising a warranty claim but without awaiting our prior
permission/clearance to restart.

7.0

Validity
Unless withdrawn the offer will remain valid till 30.06.2013

8.0

Cancellations
MPPL is entitled for full compensation of all raised material, manufacturing, engineering,
and administration costs in the event that the project or any parts of it is cancelled or
considerably postponed or the Contract is terminated. All such costs will be paid by REATL.
MPPL also entitled for full compensation of bank charges on PERFORMANCE SECURITY
GUARANTEE (PSG), if the project or any part of it has been cancelled or considerably
postponed or the Contract is terminated. The Performance security Guarantee should be
returned immediately to MPPL

9.0

The General Terms and Conditions of Sale:


Attached

10.0

Confidentiality
Please note that the contents of this letter and the documents included in our offer are to be
treated as strictly confidential and none of the information to be disclosed to any third
party.

We trust that our offer will meet your requirements and should you have any questions, or
require any additional information, please do not hesitate to contact us.

For Magnus Power Pvt. Ltd.,

________________________
Rajakumar
Director

Annexure 2(c)
Engine Catalogue

18V48/60TS

Two-stage turbocharged diesel engine

MAN Diesel & Turbo


The responsible way in leading technology

MAN Diesel & Turbo is the worlds leading designer and manufacturer of low and
medium speed engines. Our involvement with electrical power generators goes
back to 1904 when we supplied the first ever diesel generator sets to the Kiev Tram
System.
Since those early days, MAN Diesel & Turbo has never lost its technological preeminence in the large engine field. Likewise, our engines have never relinquished
their status as the most efficient combustion engines available.
More than ever before, MAN Diesel & Turbos development focus is on the environ
mental performance of our engines. Using our unrivalled grasp of large engine
technology, we aim to make our engines progressively cleaner, more powerful and
more efficient.
With our firm commitment to reducing emissions while increasing fuel efficiency
and power density, and with our active partnership with environmental institutions
and development banks, we intend to be part of the global emissions solution.

18V48/60TS Four-stroke diesel engine

The Best in its Class


18V48/60TS

A New Dimension

Two turbochargers in sequence provide a new dimension in engine performance

The diesel engine 18V48/60TS

and operational flexibility. A wide load range from 1,050 to 1,200 kW/cyl., a specific
fuel oil consumption of 171 g/kWh at 1.050 kW/cyl. and reduced NOx emissions set
a new benchmark for four stroke diesel engines.

The 48/60 type diesel engine is a perfect example of

For the two-stage turbocharged 18V48/60TS, only a

proven technology and robust design. Over 800 units

few modifications were made to the standard engine:

have been sold since the product was launched in


1988. They are now operating in a range of applica-

Adapted fuel injection nozzles

tions in power generation and marine propulsion.

Three-ring piston with higher compression ratio

Thanks to its high efficiency, the 18 cylinder engine is

Modified camshaft for enhanced Miller timing

the 48/60 engine familys best-selling configuration.

Additional exhaust gas bypass valve to avoid

Turbochargers from MAN Diesel & Turbo

smoke during engine start-up

Turbochargers are the core of this innovative new

a limited pressure ratio. A specially designed com-

concept and MAN Diesel & Turbo is the only engine

pressor, as in the TCA88/RCF23, can increase the

manufacturer that also designs and builds turbo-

pressure ratio but also has the effect of decreasing

chargers. This unique expertise translates into ex-

efficiency. The only solution to this dilemma is two-

ceptional efficiency and reliability.

stage turbocharging, also known as sequential tur-

0,76

bocharging (STC).

0,74

TC Efficiency

0,78

Two-stage turbocharging
efficient turbochargers upstream from the engine,

and tested TCA88 and TCA77 standard turbocharg-

one after the other. The result: the engine gets twice

ers in sequence. The TCA88 is located upstream and

the charge air pressure, while turbocharger efficien-

provides the low pressure turbocharger, while the

cy is increased significantly.

TCA77 forms the high pressure turbocharger, next to


the engine. In this configuration, both turbochargers

A single turbocharger, such as MAN Diesel & Turbos

can achieve pressure ratios over 6 bars and efficien-

well known TCA88, is highly efficient; however, it has

cies of more than 76 per cent.

18V48/60TS Four-stroke diesel engine

TC efficiency tot-tot

The 18V48/60TS deploys MAN Diesel & Turbos tried

TCA88 +TCA77

TCA88

0,72

The idea is simple: just place two of MANs most

2-Stage operation

0,70

TCA88/RCF23

0,68
0,66
0,64
0,62
0,60
1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

6,0

p_out / p_in compressor

18V48/60TS Four-stroke diesel engine

Standard Components, Proven Design

Low pressure Turbocharger


High pressure Turbocharger

Standard components, proven design

Lowest fuel oil consumption or NOx emissions

The overall design of the two-stage turbocharged

The excess combustion air from the turbochargers

Two-stage turbocharging is a modular system: its

18V48/60TS has been kept as simple as possible.

provides greater operational flexibility. The high

design enables most MAN Diesel & Turbo power

Apart from the modifications described above, the

charge air pressure can be used for enhanced Miller

plants to be retrofitted with this solution.

engine is standard, with the high pressure turbo-

Cycling, delivering significant fuel savings and further

charger directly mounted to it.

reducing NOx emissions.

Flexibility in fuels, flexibility in operations

The low pressure turbocharger is located upstream

As a result, the 18V48/60TS diesel engines extrem-

Like the 48/60 series standard engines the two-stage

from the engine, on its own steel frame. The combus-

ely low specific fuel oil consumption of 171 g/kWh

turbocharged 18V48/60TS can be operated with a

tion air and exhaust gas piping between both turbo-

makes it the most cost-effective in its class.

wide range of different fuels:

Alternatively, the excess combustion air can be

Heavy fuel oils with a viscosity up to 700 cst

leveraged to significantly increase the engines

Marine diesel and gas oil

Power output kW/Cyl.

Effects of Two-Stage Turbocharging

power output, up to 1200 kW/cylinder. Although this

low pressure turbocharger. Active during engine

does not save as much fuel, it does allow for a great-

Due to the unique features of two-stage turbocharg-

start-up and low part-load operation (up to 25 per

er reduction of NOx emissions within a wide opera-

ing, the 18V48/60TS can be operated continuously

cent load), it avoids smoke emissions caused by the

tion range. NOx emissions of 1480 mg/Nm make the

at shaft power outputs from 18,900 up to 21,600 kW.

lack of combustion air from the turbochargers in this

18V48/60TS the cleanest diesel engine in its power

For example, this allows power producers to operate

operation range.

range.

the engines at a normal load of 18,900 kW taking


advantage of the extremely low fuel oil consumption
and giving them the possibility of a spinning reserve
up to 21,600 kW.

18V48/60TS Four-stroke diesel engine

1050

1100
1050

1000

1800
NOx mg/Nm3 @15%O2

An air blower is situated below the steel frame of the

1100

1850

1850

1750

1740

1700
1650
1600

1580

1550
1500

Op. mode
Fuel consumption
g/kW/h

plete insulation from vibrations.

1150

1150

Op. mode

chargers is fitted with compensators, ensuring com-

1200

1200

1480
1

177

177
175
173
171

174
171

172

18V48/60TS Four-stroke diesel engine

18V48/60TS Technical Data


Overview

18V48/60TS engine
Operation mode
Performance data
Power per cylinder

Unit
kW

1
1050

2
1100

3
1150

4
1200

Tot. engine power

kW

18,900

19,800

20,700

21,600

Tot. el. genset power

kW

18,428

19,305

20,183

21,060

g/kWh

171

172

174

177

Engine type:

18V48/60TS

Engine cycle:

four-stroke

Turbocharging system:

2-stage, constant pressure

n Low

pressure TC type:

MAN TCA88

High pressure TC type:

MAN TCA77

ISO Reference conditions:


n Air

temperature: +25C (77F)

n Air

pressure: 1000 mbar

Number of cylinders:

18

Bore:

480 mm

of charge air cooler: +25C (77F)

Stroke:

600 mm

n Relative

mech. Power output, +5% tolerance

Swept volume per cyl.:

108.6 dm

Heat Rate

Engine speed 50/60Hz:

500/514 rpm

Figures are given with a tolerance of 5%, except for

Mean piston speed:

10.0/10.3 m/s

the lubrication oil consumption, which is given with a

Spec. fuel oil consumption


acc. to ISO 3046, without pumps,

acc. to ISO 3046, without pumps,

kJ/kWh

7,305

7,350

7,430

7,560

NOx emissions (dry at 15% O2)


Mean effective pressure
Spec. lube oil consumption

mg/Nm3

1850

1740

1580

1480

bar

23.2/22.6

24.3/23.7

25.4/24.7

26.5/25.8

g/kWh

0,60

0,60

0,60

0,60

A
Dimensions (mm)

Dry mass (t)

18V48/60TS Four-stroke diesel engine

n Cooling

water temperature upstream


air humidity: 30%

tolerance of 20%.

mech. Power output, +5% tolerance

General definition of diesel engine ratings


according to ISO 3046-1: 2002

9625

407

B
5410

407

C
24510

407

H
9023

407

Nom. generator efficiency:

97.5%
Abbreviations:

Cooling:
Cylinder cooling:

HT cooling water

LP-TC charge air cooler:

2-stage HT and LT cooling water

TC

Turbocharger

HP-TC charge air cooler:

2-stage HT and LT cooling water

HP

High pressure

LP

Low pressure

Starting method:

compressed air with

HT

High temperature

blower for low part load

LT

Low temperature

operation up to 25% load

4694

407

18V48/60TS Four-stroke diesel engine

World Class Service


Expert advice and assistance

PrimeServ peace of mind for life

PowerManagement by MANDiesel&Turbo

With more than 150 PrimeServ service stations and

Complementing the PrimeServ after-sales offering is

service partners worldwide and our growing network

the MAN PowerManagement concept.

of PrimeServ Academies, MAN Diesel & Turbo is


committed to maintaining the most efficient, acces-

MAN PowerManagement packages provide integrated

sible after-sales organisation in the business.

support solutions for all aspects of running a power or


co-generation plant. Individually negotiated agreements

PrimeServs aim is to provide:

can cover assistance with or delegation of the man

n
Prompt,

agement of all mechanical, electrical and thermal equip

OEM-standard service for the complete life

cycle of an installation

ment. This gives the power plant operator comprehensive

n
Training

access to the technology, experience, best practices

and qualification of service personnel at

our PrimeServ Academies to maximise the plants

and professional resources of MAN Diesel & Turbo.

availability and viability


n Rapid,

global availability of genuine, quality-as-

In short: PowerManagement by MAN Diesel & Turbo

sured MAN Diesel & Turbo spare parts via local

allows you to benefit from our specialist expertise in

outlets or our 24 hour hotline.

running a power plant while you concentrate on your


core business.

10 18V48/60TS Four-stroke diesel engine

All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific
individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of
each individual project, especially specific site and operational conditions CopyrightMAN Diesel & Turbo D2366483EN Printed in Germany GMC-AUG-06110.3

MAN Diesel & Turbo


86224 Augsburg, Germany
Phone +49 821 322-3897
Fax +49 821 322-3382
powerplant-aug@mandieselturbo.com
www.mandieselturbo.com

Annexure - 3
Fuel Specification

Fuel system related characteristic values:

The fuel system is designed to operate based on the following fuel oil
specification based on ISO 8217-2010:
Lower calorific value (LCV)
Viscosity (at 50C)
Density (at 15C)
Sulphur content
Ash content
Flash point
Pour point
Coke residue (Conradson)
Vanadium
Water
Sediment (potential)
Aluminium and silicon (total)
Total acid number
Hydrogen sulphide
Asphaltene content
Sodium
CCAI number

40230 kJ/kg
up to 180 mm2/s
max. 1010 kg/m3
up to 3.4%-wt.
up to 0.15%-wt.
min. 60 C
max. 30 C
max. 20 % wt.
max. 450 mg/kg
max. 0.5 % vol.
max. 0.1 % wt.
max. 60 mg/kg
max. 2.5 mg KOH/g
max. 2 mg/kg
max. 2/3 of coke residue % wt (Conradson)
Sodium < 1/3 vanadium, Sodium < 100 mg/kg
max. 870

Current fuel oil characteristics are not sufficient for estimating the combustion
properties of the fuel oil. This means that service results depend on oil
properties which cannot be known beforehand. This especially applies to the
tendency of the oil to form deposits in the combustion chamber, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause
difficulties.
The fuel must be free of admixtures not based on mineral oil, such as coal oil
or vegetable oils, free of tar oil and lubricating oil, free of any chemical waste,
solvents and polymers.

Annexure - 4
The Greenery layout

Annexure - 5
Land Use Map

Annexure - 6
Land Development Map

Annexure - 7
Drainage Layout

Annexure - 8
Oily Water Separation System

EcoStream
Technical information for bilge water treatment

Inside view

The EcoStream bilge water treatment system from Alfa Laval is a reliable
fully automated, single-stage centrifugal separation system to clean oily
wastewater on board vessels at sea and at land-based power plants.

Summary

The EcoStream bilge water treatment system


Overview
System requirements
System benefits

Towards cleaner oceans


What is bilge water?
Bilge water treatment
Bilge water legislation

Stable emulsions in bilge water


What are emulsions and suspensions?
Chemical usage aids stabilization
Effect on separation performance
Mechanisms for emulsion breakdown

10

Equipment
Operating principle
Key components

13

Optional components

14

Flow diagram

16

Retrofitting

16

Documentation

16

Classification

16

Spare parts, service and support

Alfa Laval EcoStream

2 Alfa Laval Marine & Diesel Equipment

Alfa Laval EcoStream

Summary
Bilge water must be treated to reduce the oil content to levels that meet
international regulations for release into the environment. This is critical
to keeping the worlds oceans and their vast marine ecosystems healthy
and productive.
The Alfa Laval EcoStream bilge water treatment system
is a centrifugal separation system for bilge water treatment
that has been approved by the International Maritime
Organization.

Benefits for owners and operators


Reduced operating costs thanks to low maintenance,
automated control, no waste disposal and an absence
of filter elements that require replacement.

This system generally cleans bilge water to less than five


parts per million (ppm) oil in water. It operates at flow rates of
up to 2,000 liters per hour to meet even the toughest bilge
water treatment applications.

Reliable, always-available system. Operates continuously,


regardless of variations in feed, oil shocks and rough
weather conditions.

As a major equipment and technology supplier to the


marine industry, Alfa Laval understands the requirements
of all treatment systems on board vessels.
We use equipment and technology know-how to build
solutions of all kinds for cost-effective and efficient operation
of vessels from engine room applications including oil treatment and fuel conditioning to waste disposal applications,
including bilge water treatment.
Our aim is to work continuously to improve customer
processes time and time again.
This document provides technical information about
the Alfa Laval EcoStream bilge water treatment system.
It includes information about the bilge water separation
process, advances in system design, system benefits
and a description of equipment.

Easy to operate. Automated control and monitoring system


integrates with existing Alfa Laval systems, providing a
single user-friendly interface.
Safe operation. A key lock switch can be set in manual
or locked position to ensure that only the individual
responsible for environmental compliance may authorize
overboard discharge.

Benefits for designers of ships and power plants


Compact, modular, easy-to-install system saves time,
space and money.
Continuous, single-stage operation requires less holding
tank volume and provides more space for payload.
Easy integration with existing communications systems
on board.

The Queen Mary 2 is equipped with two EcoStream bilge water treatment systems.

Alfa Laval Marine & Diesel Equipment 3

Alfa Laval EcoStream

The Alfa Laval EcoStream


bilge water treatment system
Cleaning of bilge water poses distinct challenges. Not only does the
composition and flow of bilge water constantly change, making continuous
and efficient treatment difficult, but treatment on board also presents
another set of constraints.

Alfa Laval
EcoStream.

4 Alfa Laval Marine & Diesel Equipment

Alfa Laval EcoStream

Centrifugal separation has proven to be a reliable, efficient


and flexible method for continuous removal of oil and other
contaminants suspended in the bilge water on board ships
and at land-based power plants.

Overview
The EcoStream bilge water treatment system from Alfa Laval
is a centrifugal separation system for treatment of large bilge
water volumes at sea. EcoStream operates at flow rates of
between 1,500 and 2,000 liters per hour and usually cleans
bilge water to less than 5 ppm.
EcoStream is easy to install for any new or existing
installation. It does not require large bilge water holding
tanks. This increases payload capacity. Compared to conventional bilge water systems, EcoStream significantly
reduces operating costs, thanks to automation and remote
control. In addition, there is no expensive filter element
replacement required.
EcoStream enables cleaning of bilge water under a wide
range of real operating conditions. It complies with the
Marine Environment Protection Committee Resolution,
MEPC 107(49), of the International Maritime Organization
(IMO), MED 96/98/EC. EcoStream is not only certified by
these organizations, but has proven its high level of performance under real operating conditions, normally below
5 ppm even when subjected to oil shock or rough weather.

Conditioning Module and Separation Unit controllers,


facilitating ease of operation.
Easy to access and maintain
Built-in service areas facilitate inspection and maintenance.
A central pillar houses all motor starters and the advanced
process controller, making the EcoStream unit easier to
service and easier to operate than other units available.
More uptime, less maintenance
Maintenance-free components, automation and remote control increase operating time and decrease service disruptions.
Durable components contribute to longer service intervals
between inspections.
Lower installation and operating costs
Thanks to pre-testing, installation requires less time and
money than installation of separate components. Automation
and remote control reduce operating costs.
Technical support
All spares, service and sales engineers are available through
the Alfa Laval International Service Network.

Dimensions

1768 mm

Treatment methods must meet individual ship requirements


and demands for safety, reliability, compactness, automation,
low maintenance and the ability to withstand rough weather
conditions. In addition, performance of the treatment system
can vary depending on the oil content and the size of the
droplets or particles present in the water and on various
operating conditions.

Faster, more secure commissioning


Pre-tested, pre-installed and pre-approved components for all
system functions make commissioning quick, easy and much
less expensive than buying separate components and
designing a bilge water treatment system.

1450 mm

Easy to install
This simple, plug-and-play installation of this factory-tested
module makes it easy to install. Pipe connections located
underneath the unit make EcoStream easy to install.

635 mm

System benefits
Compact, modular and flexible design
This provides great flexibility to install the unit in a convenient
location. A wide range of options for functionality, remote
control and other features adds more flexibility.

750 mm
Access area
1070 mm

Easy to operate
Automation and remote control make EcoStream a userfriendly, start-and-forget system. The process controller
also shares the same user interface as the Alfa Laval Fuel

1810 mm

Alfa Laval Marine & Diesel Equipment 5

Alfa Laval EcoStream

Towards cleaner oceans


Bilge water generated on board ships is a major environmental
concern for the shipping industry.

Regardless of its source, bilge water must be treated to


reduce the oil content to levels that meet international regulations for release into the environment. This is critical to
keeping the worlds oceans and their vast marine ecosystems
healthy and productive.
Efficient bilge water treatment minimizes the impact of ship
propulsion on the marine environment as well as the heavy
fines that ship operators can face for pumping oily bilge water
overboard.
Efficient treatment also reduces the need for and cost of
waste disposal ashore. Over the years, waste disposal costs
have continued to climb as local authorities enforce stricter
laws for the land-based companies that process this waste.

Bilge water contains


a mixture of water
and fluids from
various sources on
board that is treated
for clean water
discharge overboard.

Alfa Lavals bilge water treatment solution is superior to many


competing technologies with respect to the volumes of waste
generated.

What is bilge water?


Bilge water collects in a ships bilge wells, which are located
in the lowermost part of the vessel just above the hull. The
wells receive water and mechanical fluids from operational
sources, such as technical rooms, propulsion systems and
different machinery.
Bilge water also contains fluids from machinery spaces,
internal drainage systems, sludge tanks and various other
sources.

Cleaning and
maintenance

Water from purifier


sludge tanks

Drains
and leaks

Water from waste


oil tank

Tank
overflows

Condensate
from air coolers

Incidents

Clean water
overboard

Bilge
pump

Bilge water tanks

Bilge well

6 Alfa Laval Marine & Diesel Equipment

Bilge water
treatment
Bilge well

Alfa Laval EcoStream

Bilge water
composition.
Fresh water

Water

Seawater
Heavy fuel oil

Oil

Lube oil

Emulsions,
suspensions

Hydraulic oil
Organic

Particles

Inorganic
Emulsifying, corrosive

Chemicals

Other

The definition of bilge water is thus much wider in scope


than merely the contents of a ships bilge, the enclosed area
between the frames where the sides of the vessel curve in to
form the bottom.
In simple terms, bilge water contains two types of substreams: (1) flows that are reasonably continuous and predictable, and (2) flows that are intermittent in nature and difficult to foresee. The first category includes water from the
separator sludge tank and water from cleaning activities in
the ships engine room. The second category may include
soot water, leakage and incident spills from tanks and
machinery spaces.
Bilge water is thus composed of a mixture of water, detergents and other chemicals, fuel oil, lubricating oil, hydraulic
oil, cat fines, oil additives, soot and dirt. This mixture is collected in the bilge water holding tank, which generally is
maintained at an elevated temperature. This high temperature
facilitates primary gravity separation, preferably of the two- or
three-stage type, in the bilge water tank. Here, oil rises to the
top and particles settle on the tank bottom, generally dividing
bilge water into three distinct layers in the tank:
Top layer
This contains most of the oil and organic solvents and constitutes a small portion of the total tank volume. Skimming
this top layer for separate treatment is recommended.

Bilge water legislation


Bilge water treatment is an environmental application that
must meet stringent requirements of international legislation.
Disposal of untreated bilge water into our oceans is strictly
prohibited by international law and subject to heavy fines,
especially in sensitive waters.
Current MARPOL legislation stipulates that separated bilge
water containing 15 ppm or below oil in water can be disposed into international waters. Some national, regional and
local authorities, especially those governing sensitive waters,
have more stringent regulations. In the United States and in
the Baltic and North Seas, for instance, disposal of separated
bilge water is only permitted at least 12 nautical miles from
shore.
The International Maritime Organization (IMO) resolution
MEPC 107(49) specifies how to type approve equipment
used on board ships. The resolution complies with the
European Marine Equipment Directive, MED 96/98/EC.
Many manufacturers have succeeded in meeting the specified requirements for equipment certification, but much of
this equipment falls short of delivering the high separation
efficiency required under real operating conditions for bilge
water discharge.

Middle, or main, layer


This aqueous phase contains water polluted by oil, chemicals and particles in emulsified form. This is fed to the bilge
water treatment system.
Bottom layer
This contains solids and heavy sludge, which should also
be removed for separate treatment.
Alfa Laval Marine & Diesel Equipment 7

Alfa Laval EcoStream

Stable emulsions in bilge water


Separation of oil and particles from bilge water is becoming increasingly
challenging, due to the presence of stable emulsions and suspensions.
Emulsion and suspension formation and stability are of major concern in
the context of bilge water treatment.
What are emulsions and suspensions?
By definition, an emulsion is a mixture of two immiscible
liquids. An oil-in-water emulsion consists of small oil droplets
dispersed in a continuous water phase. A suspension is a
mixture in which solid particles are dispersed in the continuous water phase.
Emulsions, or small droplets of one liquid (the dispersed
phase), can form in the other liquid (the continuous phase)
under agitation, such as during pumping or throttling in
valves. Droplets of oil dispersed in water generally coalesce,
or combine, into larger droplets because oil is not soluble
in water.
Increasing the droplet size helps facilitate separation.
The presence of surfactants, such as detergents, soaps
and other surface-active compounds, however, may
contribute to stabilization of small oil droplets. This
makes separation very challenging. High centrifugal force
is then required to separate the small droplets that do
not spontaneously separate when subjected to gravitational force.
Emulsion stabilizers may consist of:
Low molecular weight surface-active compounds, or
surfactants, that reduce the surface tension of the oil-water
interface and thereby create small droplets that contribute
to emulsification.
Polymers and other macromolecules form a film around
the emulsion droplet to establish a physical barrier to
coalescence and thereby stabilize emulsions further.
Fine particles can accumulate and adsorb at the oil-water
interface to form a physical barrier around the emulsion
droplets.

Chemicals usage aids stabilization


Emulsion stabilizers may originate from a variety of sources in
the engine room from the use of cleaning detergents, from
lube oil additives and so on. Clearly, the use of chemical substances on board is excessive.
Chemicals on board are used for: cleaning and maintenance,
treatment of water, improving fuel quality, and improving the
quality of lubricating oil.
8 Alfa Laval Marine & Diesel Equipment

What used to be lubricating and hydraulic oils of relatively


elemental composition, based on simple mineral oils, are now
complex formulations, sometimes based on synthetic oils and
incorporating a variety of additives.
Modern lubricating and hydraulic oils have a greater ability to
take up water due to the action of detergents. Likewise,
cleaning chemicals have a great ability for oil and dirt uptake.
Stabilizers may also occur naturally in the oil. These stabilizers
concentrate at the oil-water interface and lower the interfacial
tension, thus stabilizing the liquid mixture.
Some chemical residuals generally end up in a vessels waste
treatment system or holding tank. The bilge water treatment
system, in particular, processes a heavy load of chemical
residuals.
Chemical usage in the engine room inevitably causes the formation of stable emulsions and suspensions as well as some
form of environmental impact. Most chemical manufacturers
claim that their products do not stabilize emulsions in bilge
water. But the use of surface-active chemicals make many
products contribute to the formation of stable emulsions.
Usage of chemicals always causes some type of compromise
between cleaning efficiency and separation efficiency on the
one hand and environmental friendliness on the other.
Alfa Laval strongly recommends the use of quick-separating,
environmentally friendly and non-toxic detergents. Choosing
chemicals that are compatible, non-toxic, biodegradable and
non-emulsifying, helps prevent problems downstream.

Effect on separation performance


The formation of stable emulsions and suspensions affects
separation efficiency. Many conventional technologies fail to
split stable emulsions and remove suspended colloidal particles from the water phase. This often results in equipment
malfunction because separation of oil below 15 ppm is not
achieved or because of clogging from excessive solids.
Understanding the factors that contribute to the formation
and breakdown of stable emulsions is essential to understanding why centrifugal bilge water treatment systems can
efficiently separate bilge water, despite a high concentration
of stable emulsions.

Alfa Laval EcoStream

High centrifugal force in


the separator contributes
to coalescence and
flocculation, which aid
emulsion breakdown.

Oil

Water

Solids

Feed

Flocculation of particles

Mechanisms for emulsion breakdown


There are different mechanisms for emulsion destabilization
and breakdown, including coalescence and flocculation.
Coalescence is a process where two or more droplets
collide, resulting in the formation of one larger droplet.

Coalescence of droplets

Flocculation is a process by which two or more particles


aggregate without losing their individual identities.
A high centrifugal force induced in a centrifugal separator
greatly contributes to the flocculation of small particles.

A high centrifugal force induced in a centrifugal separator


greatly contributes to the coalescence of small droplets.

A high alkaline pH value promotes flocculation. The pH


value provides a measure on a scale from 0 to 14 of the
acidity or alkalinity of a solution.

Elevated temperature accelerates the rate of coalescence


by increasing the probability of the droplets to collide and
by decreasing the viscosity of the continuous phase.

Chemical flocculants decrease or cancel the repulsive


electrostatic forces between particles in a suspension,
thus promoting flocculation.

Chemical demulsifiers decrease or cancel the repulsive


electrostatic forces between droplets in an emulsion,
causing droplet coalescence.

What parameters affect separation efficiency?


Centrifugal separation relies on the difference in density among
the various components present in emulsions or suspensions.

The expression states that the greater the difference in density,


the greater the efficiency. However, the density difference is not
the most important parameter affecting the separation efficiency.

Stokes Law (below) describes the settling velocity (vg ) of a


particle or droplet when subjected to gravitational force, such as
static settling in a tank, which in turn determines the separation
efficiency. The general formula is:

The sedimentation velocity increases exponentially with the


droplet, or particle, size. This means that the smaller the droplet
or particle, the more challenging the separation task.

g =
g
d
d
c
c
g

d 2 (d c)
g
18 c

the sedimentation velocity due to gravity

For separation of small droplets and particles, which are found


in the stable emulsions and suspensions in bilge water, gravity
alone is not sufficient. In a centrifuge, the term (g) in the expression is replaced by (w2r), the centrifugal force, which is several
thousand times greater than the acceleration due to gravity.
Therefore, even droplets and particles that are only a few
micrometers in size can be efficiently separated.

the diameter of the dispersed droplet/particle


the density of the dispersed phase
the density of the continuous phase
the viscosity of the continuous phase
the gravitational acceleration

Another important factor that has a positive effect on separation


efficiency is low viscosity. The viscosity of the continuous phase
affects sedimentation velocity, which increases in inverse proportion to the viscosity. Therefore, any medium with low viscosity,
such as a continuous water phase, facilitates separation.

Alfa Laval Marine & Diesel Equipment 9

Alfa Laval EcoStream

Equipment
Environmental protection requires reliability. This is how Alfa Laval
has met the bilge water treatment challenge.

Operating principle
A positive displacement feed pump with variable frequency
drive control directs oily water from the bilge water settling
tank or equivalent to the system. The pump provides a feed
range of between 1,500 and 2,000 liters per hour. The
process liquid should always maintain a pH value above five.
An optional chemical dosing unit can be connected after the
pumping stage although chemicals usually are not required
to accomplish efficient bilge water treatment.

water holding tank in order to avoid re-contamination. This


helps make bilge water handling more efficient.

Bilge water then passes through a dual basket strainer which


traps large particles from the fluid before entering a heat
exchanger, which raises the fluid temperature to required
levels, generally between 60 and 95C, for optimum separation efficiency.

Forwarding pump
An eccentric screw pump with variable frequency drive
control.

A three-way changeover valve then directs the fluid to the


separation stage if all process conditions, such as feed
temperature, feed pressure and separator speed, fall within
preset process values. If any process condition is not met,
the valve re-circulates the fluid back to the bilge water
settling tank.
A high-speed centrifugal separator continuously processes
large volumes of bilge water. The oil outlet continuously discharges out-separated oil and emulsions. Solids that collect
at the separator bowl periphery are discharged intermittently
to a cyclone, which reduces the velocity and energy of the
discharged volume. Discharge occurs at preset intervals,
which is generally set at 20 minutes, depending on the
installation. Solids are then directed to a sludge, or waste
oil, collecting tank.
A built-in water pump, or paring disc, continuously discharges separated bilge water through the water outlet.
The destination of the separated bilge water depends upon
its oil content, which is continuously monitored at an isokinetic sampling point by an oil-in-water monitor.
If oil content is less than or equal to 15 ppm, the separated
bilge water can be pumped either directly overboard or to a
clean bilge water holding tank for discharge overboard later.
If oil content exceeds 15 ppm, the effluent is re-circulated,
preferably to the cleanest part of, the bilge water settling tank
for re-processing.
As an alternative, separated bilge water with an oil content
just above 15 ppm can be directed to an almost clean bilge
10 Alfa Laval Marine & Diesel Equipment

Key components
EcoStream makes the best use of available space and
provides flexibility and easy access for operation and maintenance. These key EcoStream components are more fully
detailed later in this section:

Strainer
A dual basket strainer of mesh size 1.5 mm.
Heat exchanger
A shell-and-tube heat exchanger using steam as its heating
medium.
Three-way changeover valves
Two three-way changeover valves handle bilge water at
critical junctions.
Constant pressure valve
A fast-acting, high-precision constant pressure modulating
valve handles the required backpressure with accuracy.
Transmitters
Electronic transmitters monitor temperature and pressure.
Separator
The BWPX 307 high-speed centrifuge uses the most modern
fluid dynamics technology for high separation efficiency.
Control cabinet
Two separate compartments houses the process controller
and the electric power functions.
Process controller
The EPC 50 process controller facilitates monitoring and
control of all EcoStream functions, which are displayed in
clear text and on a mimic display.
Oil-in-water monitor
Certified according to IMO resolution MEPC 107(49), this
in-line unit accurately measures the content of oil in water.

Alfa Laval EcoStream

Components in the system


Pump unit
The pump unit consists of a stand-alone compact pump
module, which is designed for ease of installation and ease
of accessibility for maintenance.
Thanks to its variable speed control, this screw pump easily
handles changing fluid capacities and enables adjustment of
the feed rate setting during operation. The feed rate ranges
between 1,500 and 2,000 liters per hour.
To protect the pump from dry running, the unit is equipped
with a water-priming device, which is automatically activated
upon startup. This water-priming device may also be activated manually, whenever necessary. The pump has a pressure relief valve, pressure gauges and a non-return valve on
the discharge side.
Strainer
To trap large foreign particles suspended in the bilge water
that may cause unnecessary operational disturbances, a dual
basket strainer with a mesh size of 1.5 mm is installed as a
safety measure.
Heat exchanger
This shell-and-tube heat exchanger uses steam as the
heating medium. All heater parts that come into contact with
the bilge water are made of cupronickel, a corrosion-resistant
alloy. A proportional integral (PI) temperature controller accurately maintains the temperature set point within 2C, even
under variable bilge water feed conditions. This is especially
important to achieve high separation efficiency. Installation in
a horizontal position reduces the risk for build up of condensate and provides easy access for maintenance.
Separation unit
The BWPX 307 high-speed centrifuge utilizes the latest
achievements in modern fluid dynamics technology. Designed
for continuous, high-efficiency separation of large bilge water
volumes, the centrifuge handles throughput capacities of
1,500 to 2,000 liters per hour. Its unique design provides
reliable operations, even when subject to oil shocks and
rough weather conditions.
The patented Alfa Laval disc inlet, Optiflow, gently accelerates
bilge water into the separator bowl with a minimum of
shearing and foaming. This greatly improves separation efficiency by preventing the splitting of drops and the formation
of further emulsions.

Oil-in-water monitor according to IMO resolution MEPC 107(49).

Oil-in-water monitor
This in-line unit monitors the oil content of separated bilge
water in compliance with IMO Resolution MEPC 107(49).
It is capable of monitoring oil content from zero to 30 ppm
at sample temperatures of up to 65C.
To minimize response time, the iso-kinetic sampling point of
the monitor is located as close as possible to the separation
stage. Before processing occurs through the monitor, the
sample passes through a cooler, which is used when separation temperature exceeds 65C, to prevent damage to the
monitor from excessive heat.
Two independent alarm circuits come with a factory setting of
15 ppm, but may be set independently to indicate oil content
in water ranging from two to 15 ppm. An alarm setting above
15 ppm is impossible.
Three-way changeover valves
Two pneumatically activated three-way changeover valves
regulate bilge water at critical junctions. The first directs bilge
water to the separation stage for treatment, and then recirculates bilge water that does not meet pre-set conditions
back to the bilge water settling tank. The second routes
separated bilge water with oil content that is less than or
equal to 15 ppm to a holding tank for discharge overboard
later or pumps the water directly overboard.
During an alarm situation when any preset condition is not
met, loss of operating air pressure or power failure, the threeway changeover valves automatically shift to re-circulation
mode, thus preventing overboard discharge of any bilge
water with oil content exceeding 15 ppm.

The new disc-stack design provides the maximum surface


area possible for separation. Specially designed concentrator
distribution holes and caulk configuration further optimize
separation efficiency.

Constant pressure valve


This fast-acting, high-precision constant pressure modulating
valve prevents the formation of air bubbles during the separation stage and thereby helps insure the accuracy of the oil-inwater monitor. It is installed after the separator.

A speed sensor and an optional unbalance sensor monitor


the mechanical status of the separator. A cyclone, installed
in the sludge outlet, provides ventilation and reduces the
velocity and energy of the discharge volume.

Whenever solids or sludge are discharged from the separator


bowl, additional air pressure is applied to the valve to prevent
any untreated bilge water from penetrating and polluting the
system downstream.
Alfa Laval Marine & Diesel Equipment 11

Alfa Laval EcoStream

Transmitters
Electronic transmitters provide accurate readings for pressure
and temperature and improve control to achieve high separation efficiency.
Sampling cocks
Situated before the separation stage and after the three-way
changeover valves, these sampling cocks enable analysis
of bilge water samples and provide an alternative way to
measure the accuracy of the oil-in-water monitor.
Control cabinet
Centrally located to monitor all EcoStream functions, the
control cabinet has two separate compartments. The lower
compartment contains all electric power functions, such as a
multi-transformer, for power supplies in the range of 230 to
690 V, all motor starters, pump unit speed control, power
supply for the optional chemical dosing unit and all pneumatic
control devices. The upper compartment contains the
Alfa Laval EPC 50 computer-based process controller and
operator panels.
Process controller
The EPC 50 is the latest generation of the Alfa Laval computer-based process controller. Easy to operate, the unit provides fully automated advanced monitoring and control of all
EcoStream functions. To assist with trouble tracing, an alarm
log registers the last 31 alarms. It also records time when the
alarm appeared, time until the alarm was reset and the
sludge discharge time interval.
The process controller has several built-in self-cure functions
that automatically activate to ensure continued operation
should a system problem occur. A proportional integral (PI)
temperature controller accurately maintains the temperature
set point for separation within 2C, even under variable
bilge water feed conditions.
Standard hardwired input and output signals include:
Emergency stop button,
Emergency shut down (ESD),
Process shut down (PSD),
Common alarm indication, and,
Process status indication.
The EPC 50 process controller is based on the same hardware used in other Alfa Laval units, making it easy to use for
operators who are already familiar with this equipment.
Operator panels
A push button and light-emitting diode station displays the
status of cleaned bilge water for discharge overboard and for
re-circulation, the pumping stage, the electric motors,
optional chemical dosing units and optional automatic
cleaning unit for the oil-in-water monitor.
A

mimic display continuously indicates the operation mode of:


Feed to the separation unit or re-circulation,
Cleaned water for discharge overboard or re-circulation,
Pressure and temperature transmitters.

12 Alfa Laval Marine & Diesel Equipment

EPC 50 process controller.

More process data are easily accessible by simply pressing


a button. These include feed temperature, feed pressure,
water outlet pressure, oil content in cleaned water, separator
bowl speed and total operating hours. All critical process
parameters and operation mode, including start-up, standby,
pre-production, production and stop, are displayed in
clear text.
A key lock switch that controls discharge of separated water
is also located on the panel. Bypass, or locked, position recirculates separated bilge water, regardless of its oil in water
content. Inserting the key enables selection of automatic
position, which directs bilge water with oil content of 15 ppm
for discharge overboard.
It is also possible to set the limit for overboard discharge
lower than 15 ppm at five ppm, for instance. This enables
safe discharge in environmentally sensitive waters, where
lower oil in water content is required by regulatory bodies.
Located next to the LED panel, the operator panel controls
the feed rate of the variable frequency drive feed pump.

Alfa Laval EcoStream

Optional equipment
The EcoStream system offers these equipment options to provide
greater flexibility.

Chemical dosing unit


Under extreme conditions, centrifugal force alone may not
be sufficient to deliver high separation efficiency for satisfactory treatment of the bilge water. This is usually the case
when large quantities of suspended solids, such as soot or
detergents, are present in bilge water.
For these conditions, an optional chemical dosing unit efficiently handles strongly emulsified oil as well as suspended
colloids.
Chemicals should only be added when a combination
of high separation temperature (95C) and low flow rate
(1,500 liters per hour) is insufficient to separate bilge water
to contain 15 ppm or less oil in water.
Alfa Laval recommends the use of safe and environmentally
friendly Alpacon chemicals, MP 300/302. The combination
of these water-based additives promotes demulsification
and flocculation to achieve clean water with less than
15 ppm for more difficult feed compositions.
Automatic self-cleaning filter
If the feed water is expected to have a high solids or fiber
content, installation of an automatic, self-cleaning filter is
recommended. This may be necessary, for instance, if the
risk of overflow from black and grey water tanks into the
bilge wells exists.
Removing fibers and other coarse solids helps prevent
clogging of passages, such as the distribution holes in the
separator disc stack. This prolongs service and maintenance
intervals, which may otherwise be unacceptably short.

The CIP unit reduces downtime and maintenance manhours and saves money. It also minimizes the potential risk
for mechanical damage of vital bowl parts.
Automatic cleaning device for the oil-in-water monitor
An automatic pneumatic cleaning device for the oil-in-water
monitor is available as an alternative to manual cleaning of
the measuring cell in the oil monitor.
The cleaning device activates at every sludge discharge,
ensuring accurate monitoring of oil content by continuously
cleaning the measuring cell in the oil monitor.
Serial bus connection
Fully remote operation of the EcoStream is possible by
connecting the process controller via serial bus to an
external computer or communications system.
This provides complete coordination with a Central Control
System (CCS) or a plants Integrated Administration and
Control System (IACS). Proprietary field bus interface
boards, according to Profibus DP or Modbus RTU standards, are installed in the process controller. This enables
communication to external automation systems. Most local
functions can be replicated with the use of the field bus interface boards.
Please contact Alfa Laval if other protocol boards,
such as CANopen, DeviceNet or InterBus, are required.
Customers assume responsibility for coordination of programming on the remote side through their automation
providers. Alfa Laval provides documentation describing
the protocol for the system developers.

Sludge removal kit (SRK)


When installation of EcoStream on top of a sludgecollecting tank is impossible, an optional sludge removal kit
(SRK) is available.
As part of the oily water pre-treatment stage, this small,
intermediate sludge tank comes equipped with a pneumatically driven sludge removal pump, level controller and
level switch.
Cleaning-in-place unit
An optional cleaning-in-place (CIP) unit is available to
enable cleaning of separator bowl parts without dismantling the separator.
Alfa Laval Marine & Diesel Equipment 13

Alfa Laval EcoStream

Flow diagram
 Two-stage bilge water

 Automatic self-cleaning filter

settling tank
Pre-heats the bilge water.

 Steam pre-heater

(optional)
Removes coarse solids and fibers.

 Chemical dosing units (optional)

 Pressure transmitters

Enhances separation efficiency if


stable emulsions are present.

Measures the pressure in the water


inlet and outlet and signals this information to the process controller,
which monitors pressure to ensure
remains within acceptable limits.

 Feed pump with


variable speed control
Transfers liquid to the steam
pre-heater.

 Dual basket strainer

Raises temperature of the liquid


to the required treatment temperature.

 Temperature transmitters
Measures the temperature of the
liquid from the pre-heater and
signals the process controller.

Temperature controller

Traps large particles from the fluid


before entering the heater.

From
bilge wells

From drains
and leaks

Alerts operator when the temperature exceeds, or falls below, a preset limit and acts as a backup to
provide temperature control should
the temperature transmitter fail.

Recycling to tank
Feed recycling


Alpacon Alpacon
MP 300 MP 302

VFD
PT

Feed inlet




14 Alfa Laval Marine & Diesel Equipment

Alfa Laval EcoStream

Three-way changeover valves

BWPX 307 high speed

Directs bilge water from the tank


to the separation stage and from
the separation stage either to
pump for discharge overboard if
it contains less than 15 ppm oil
in water or back to the bilge water
settling tank if these conditions
are not met.

 Constant pressure

centrifugal separator
Continuously separates large
volumes of bilge water.

modulating valve
Prevents the formation of air bubbles during the separation stage
and thereby helps insure the accuracy of the oil-in-water monitor.

 Oil-in-water monitor
Continuously measures oil content
of cleaned bilge water and compares these measurements to a
pre-set value.

Cyclone

Intermediate sludge tank with


sludge pump (optional)
Temporarily stores sludge for waste
processing on shore.

Reduces the velocity and energy of


the discharged volume of solids
before reaching the sludge outlet.

PT

QT

Ventilation

Clean water
outlet




QC

TC

TT

TT

Sludge outlet

Alfa Laval Marine & Diesel Equipment 15

Alfa Laval EcoStream

Retrofitting

Documentation

EcoStream is ideal for replacing older bilge water


treatment systems. Its compact size easily fits into
any available space.

Alfa Laval supplies each EcoStream bilge water treatment system with full documentation either as paper
copies or as PDF (Portable Document Format) files on
a CD-ROM. The instruction manual, which can also
be made available in most major languages, covers:

To facilitate transport through small passageways,


EcoStream can also be divided into four parts:

A separator with a frame,


Valve and piping rack,
Feed pump, and,
Control cabinet.

Classification
society approval
Alfa Laval ensures that the EcoStream fulfils the
requirements of all major classification societies.
Upon request, Alfa Laval delivers the EcoStream with
an individual test certificate. This includes approval by
the society of the main components as well as workshop testing of the complete module. Several key
components are also type approved by the leading
classification societies.

16 Alfa Laval Marine & Diesel Equipment

Safety
System description
Operating instruction
Parameter list
Alarms and fault finding
System reference/installation instructions
Separator manual
Spare parts catalogue
Component descriptions

Spare parts,
service and
support
Alfa Laval provides spare parts kits for all service and
maintenance needs. Global technical service, training
and support are available throughout the lifetime of
the EcoStream.

Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement
of this publication would be gratefully appreciated.
Copies of this publication can be ordered from your local Alfa Laval company.
Published by:

Alfa Laval Tumba AB


Marine & Diesel Equipment
SE-147 80 Tumba
Sweden

Copyright Alfa Laval Tumba AB 2004.

Alfa Laval in brief


Alfa Laval is a leading global provider
of specialized products and engineering solutions.
Our equipment, systems and services
are dedicated to helping customers
to optimize the performance of their
processes. Time and time again.
We help our customers to heat, cool,
separate and transport products
such as oil, water, chemicals, beverages, foodstuff, starch and pharmaceuticals.
Our worldwide organization works
closely with customers in almost 100
countries to help them stay ahead.

How to contact Alfa Laval

EMD00050EN 0412

www.fotoskrift.se

Contact details for all countries are


continually updated on our web site.
Please visit www.alfalaval.com to
access the information.

Annexure 9(a)
Elevation & Layout of FGD Plant

Annexure 9(b)
Technical Description of FGD Plant

Specification for FGD System


Scope of Supply and Services
Dhaka Southern Power Generations Ltd.
55 MW HFO Power Plant

Nababgonj,Dhaka.

November 2013

3
1 Project Profile
Your company has 3 fuel boiler, dust removal equipment, but you have no
desulfurization equipment. Therefore SO2 is out of gauge and need to revise. After our
careful consideration, we decided to adopt to add a set of desulfurization dust removal
equipment to back of the fan. In principle, this project adopts the single (sodium) process,
equipment adopts desulfurization tower desulfurization system, so as to meet the local
environmental allowed emissions and ensure the desulfurization effect. Below we will quote
according to the single boiler design.

The technology is mature, with high absorption, high efficiency of utilization, low
operation maintenance cost etc. It provided advanced equipment and materials, ensure to meet
the latest industrial standard requirements of the quality , services and the equipment.
2 Design Basis and Indicators
2.1 Flue Gas Parameters
Flue Gasfor one furnace80000-90000 m3/h
Furnace flue gas outlet temperature350OC Guide equipment import of flue gas
temperature
So2 content2500-3700mg/m3
2.2 Desulfurization Agent Quality
Main Desulfurization Agent90caustic soda flakes
2.3Codes and Standards
The Integrated Emission Standard of Air PollutantsGB16297-96
Industrial furnaces standards for the discharge of atmospheric pollutants
GB9078-1996
Industrial boiler and furnace wet flue gas desulfurization engineering technical
specificationsHJ462 -2009
Standard of noise at boundary of industrial enterprisesGB12348-90

GBZl
GBZ1-2002
Concrete structure design codeGBJ10-89
Welds technical specification for concrete structuresJGJ/T114-97
Industrial metal pipeline design specificationsGB80316-2000
Industrial equipment and pipeline insulation engineering design specifications
GB50264-97
Pipe rack first part: technical specificationsGB/T17116.1-1997
Pipe rack second part: pipe connection partsGB/T17116.2-1997
pipe supports and hangers third partIntermediate fittings and architectural structure
fittingsGB/T17116.3-1997
Water supply and drainage pipeline engineering construction and acceptance specification
GB50268-97
Water structure construction and acceptance specificationGBJ141-90
Stationary steel straight ladderGB4053.1-93
Stationary bevel steel ladderGB4053.2-93
Stationary industrial protective barrierGB4053.3-93
Fixed steel industrial platformGB4053.4-93
Industrial enterprise lighting design specificationsGB50034-92
Low voltage distribution design specificationsGB 50054-95
General electric equipment distribution design specificationsGB 50055-93
Building structure load standardGBJ9-87
Building ground design specificationsGB50037-1996

Architectural lighting design standardsGB50033-2001


Building lightning protection design specificationsGB 50057-94
Earthquake Resistant Design CodeGB50011-2001

Structure seismic design codeGB50191-93


Industrial equipment pipeline anticorrosion engineering construction
and acceptance specificationHGJ229-91
Fluid delivery with stainless steel seamless steel pipeGB/T14976-94
Fluid delivery with seamless steel tubeGB/T8163-1999
Stainless steel seamless steel pipe
GB2270-80
Steel welding atmospheric vesselJB/T4735-1997
Stell Buildings and BridgesGBJ17-91
Equipment and flue of the general principles of the thermal insulation technology
GB4272-92
Code for design of buildingGBJ7-89
Steel structure construction and acceptance specificationGB 50205-95
2.4

Design Objective
According to the national Industrial stoves standards for the discharge of

atmospheric pollutantsGB9078-1996, Considering the total quantity control and the


improvement of environmental protection standardThe desulfurization process designs
desulfurization efficiency90the emission concentration of SO 2100 mg/Nm 3
ringelman emittance1level.

2.5 Scope of Supply


The flue gas furnace production line (desulfurization) complete set of equipment
managementthat isthe original equipment modification installed internals, increase a new
efficient desulfurization tower, the new equipment export increase pipeline and fan
connection. After the transformation, all things keep the same, just change the flue gas system,
desulfurization tower system, desulfurizer preparation system and other systems carry
information, design, construction, manufacture, installation, debugging and training. Reform
its internal structure, etc.

3 Technical Principle
3.1 Desulfurization adopts TFGD
Single (sodium) process is to use soluble alkaline clear liquidmainNaOH or
Na2 CO3as an absorbent to absorb SO 2 .Because in the process of absorption liquid, it
use the same type of alkali, so called single process.

3.2 Desulfurization principle


Single process uses NaOH or Na2CO3 alkali liquor to absorb SO2, produce HSO32-SO32-and
SO42-reaction equation as below:
desulfurizing process

Single alkaline process desulfurization serves caustic soda flakes seriflux as the main
desulfurization agent, soda is continuously recycling. Because of this, the system will not
appear scaling blocking phenomenon, so the operation is safe and reliable.

Due to the quick rate of sodium alkali absorption and SO2 reaction, comparing with
calcium base, it can achieve a very high SO2 removal rate in smaller liquid gas ratio
condition.
3.3 Dust Removal Principle and Original Equipment Modification
After high atomization nozzle, doctor solution will blow into small droplets, and
will have full contact with SO2. the dust in the flue gas was set down, SO2 is
piecewise desulfurization neutralization, so as to achieve the effect of
desulfurization
Remark The production does not suitable for TFGD desulfurization,because
TFGD exists the risk of Blocked.
3.4 Technics Characteristic
a Advanced technology, complete set of equipment, set sulfur removal
integration
This technology fully ensure the new and old equipment is mixture with flue gas
and doctor solution. After absorption, adsorption and chemical reaction, it can
completely remove the flue gas dust and sulfur dioxide emissions, to meet environmental
protection requirements. The equipment was awarded the national patent in 2010.
bLow operating cost
The design using sodium as the circulation desulfurization agent and efficient
absorption tower,has low liquid gasrate, low circulationand the desulfurization agent
and electric water consumption is low.
cSystem stable operation
Using sodium as the circulation desulfurization agent in the circulation process is
without scale and blocking phenomenon to water pump, piping, equipment, and the
system can be stable operation.
dHigh Desulfurization efficiency
For the absorption efficiency of sodium alkali desulfurization agent is much higher

than albany grease, at the same time, using the high absorption tower design, its
desulfurization efficiency is 90 ~ 97%.
4. Process design
The project adopts advanced technology, stable operation of sodium - alkali TFGD,
taking the new and high efficiency desulfurization dust removal technology. Below is the
overall design principle:
1) To meet the environmental emissions standards and design index and client's
requirements
2) To use a set of composite desulfurization tower and a set of utility system
configuration;
3) In the premise of guarantee system reliability, rational distribution, and as far as
possible to use of the existing flue, reducing investment cost and floor space;
4) Saving energy and reducing consumption, under the precondition of meeting the
indicators and sulfur removal system to ensure the best absorption liquid gas ratio and other
control parameters, in order to decrease the desulfurization agent consumption, energy and
water consumption.
5) Not set up the bypass flue;
6) This system is fully considered the change of SO2(that is, the range change of
15002300mg/m3and combined with the gas flow parameters 50100 to design.

4.1 Process design parameters (sulphur content 5-2%)

Content
Inlet flue gas temperature
Gas flow
SO2 concentration

Unit
Data

Remark

350

Fan outlet temperature

m3 /h

80000-90000

Provided by the
manufacturer

mg/ m3

2500-3600mg/m3
3.514m

thionizer

XGP-20

specification
m

2.5X14m

Twin

Composite efficient

(Diameter x height)
Towers

desulfurization tower

Tower gas rising velocity

m/s

2.5

liquid-gas ratio

L/m3

mg/Nm3

100250

kg/h

12-15

mg/m3

75

Export so2 concentration


The amount of caustic soda
consumption
Export flue gas to carry water
content

Spray tower
Desulfurization

system
Pa

900

desulfurization

pressure drop
resistance
System added water
Absorption

tower

Kg/h

annual

15

design

service life
observation every week
Production staff

person/ class
and clearing channel

System installed power

kW

30

power consumption

kWh

15

service power of the


system
desulfurization efficiency

90

4.2 Process overview


Exhaust gas of dust removal, desulfurization equipment is from the original equipment
out into efficient desulfurization case for flue gas treatment. Flue gas is through the high
efficiency desulfurization tower efficient filter layer. And this filter layer with special design,
flue gas going through the filter layer, enhance the efficiency of absorption. And after
desulfurization tower top three layers of atomized spray absorption area, desulfurization agent
atomized into tiny droplets collision adsorption, absorption of SO2, complete gas
desulfurization dust absorption, and then into the efficient desulfurization tower at the back of
the mist device. The flue gas of the droplet capture down, mist eliminator is equipped with

flushing device, timing to wash. Flue gas is through the mist eliminator (vice tower) to
remove the liquid gas after the reconstruction in a period of pipeline to gas pipeline
Single (sodium) process mainly includes1 Flue gas piping system2 clarification
systemthionizerpool3 Desulfurization agent preparation system4 Circulating water
tank system5other system.
4.3 Formulate
4.3.1 Flue gas system
Dust gas by the transformation of the original equipment out enter the sulfur
removal system. Exhaust gas is through efficient desulfurization tower, dehydrator (vice
towe) equipmentfinishing the flue gas desulfurization dust cleaningand then through the
fan and chimney to high emission
Desulfurization main equipments side is not setting bypass flue. Pipeline are all
made of steel structureamong import and export pipeline desulfurization take the
preservative treatment. The increasing pipeline internal all take the preservative
treatment.
1Pipeline
According to the possibility of the worst operating conditionse.g.temperature,
pressure, flow rate and the content of pollutantsto design the pipe.
Pipeline design can bear below loadself weight of pipelinewind loadsnow load
seismic loaddust accumulationthe weight of the lining and so onSome places add line
support.
Pipe is a gas tightness of welding structureand all non flange connection interface are
continuous weldingcomplying with the above rules.
Piping layout can ensure condensate emissionswon't have water or condensate
fluid accumulation.So pipeline can provide the measures accumulation of low point
drainage and prevention condensate. In any case expansion joint and damper are not
arranged in low point

Pipe external will fully reinforcement and support, in order to prevent the chatter and
vibration, and to meet stable operation in all sorts of flue gas temperature and pressure
(including stratification and uneven).
All the way of anti-corrosion protection should only use external reinforcement, do
not use internal stiffeners or support
Pipe external reinforcement uniform spacing arrangement.Use reinforced uniform
size or try to reduce the size of reinforcementAnd add the beauty of outer appearance.
When arranging the reinforcement,we need to consider preventing water
All piping in the appropriate position is equipped with a sufficient number and size of
manhole door and soot cleaning hole, so that the pipeline (including expansion joint and
damper) can be maintenance and check and remove soot formation. The design of the pipeline
will minimize piping system pressure drop, and its layout,sharp and internal partsSuch as
turning guide platehave optimization design.
4.3.2 Flue gas desulfurization dust removal system
1design consideration

See abovecodes and standards


2design objective
1desulfurization efficiency90%Ringelmann shade scale1 Dust emissions
100mg/m
Sulfur emissions100250mg/m
2Equipment service life15years.
3design parameterProvided by manufacturer
1Furnace shapeoil burning boiler
2Treatment medium SO2 produced from the furnace.
3Day of working time 24 hours
4Equipment flue gas inlet temperature350
3

5Gas flowmanaging gas flow80000-90000m /hworking condition


6 Sulfur inlet concentration2500mg/m-3600mg/m
7Sulfur out concentration100-250mg/m

4Design Philosophy
1Adhere to the advanced ,reliable economic principle, so as to meet the domestic
advanced level
2Environmental protection standard is stricter than state specified standard.
3All equipment are based on domestic processing production, important parts
(shower nozzle, effuser, etc.) are made of strong corrosion resistant material.
4The dust removal system installation, operation does not affect the original
production facility structure and process.
5The sulfur removal technology is advancedtaking the integration of sulfur
removal which was produced by our company:A new efficient desulfurization
tower.The project has been granted the national patentPATENT NO
ZL200920119623.5
System configuration is reasonable and completecomplying with the relevant state
safety norms.
Safe and reliable operationconvenient maintenancelow operating costthe
reasonable and reliable connectionand can quickly input and switching.
6 The main part of the dust removal system (dust desulfurization equipment) is
transformed in the original equipment, increasing the length of 400 mm 6 branches filter layer
and open the roof.
7Steel structure joint parts adopt standard joint.
5Dust removal system design and limit of works area
1Equipment pipeline door system design
2Desulfurization dust removal equipment designincluding pipelineremark
equipment connected air ducta new efficient desulfurization towera mist eliminator
and to rebuild original dust removal equipment.
3The range of construction scheme is

for fuel boiler flue gas purification and removal sulfur project design, equipment
production, transportation, guide installation and debugging, training and comprehensive
work
4The scheme does not include pool, supplement water and so on.
6Desulfurization system design and Equipment Selection
1Desulfurization system process
According to our companys experience, in order to achieve relatively satisfied result.
Below is the technological process:
Original dust removal equipmentdraught fanEfficient desulfurization dust
removal equipment dehydratorchimney net gas emission
Determination of the pipeline systemAccording to the economic flow velocity
1315m/s and through the pipe flow calculationthe diameter of the pipe system
is1500mm.
2Desulfurization system design features
According to client's requirementcombining with our successful examples and
experienceaccording to the principle of seeking truth from facts, learning from others's
strong points to offset one's weakness and optimal designBelow is the technical design
for flue gas desulfurization system
2.1 Desulfurization system is running in a negative statemaximum manage So2 in
the production process,in order to ensure not affect furnace work.
2.2 Sulfur removal system designequipment selection emphasize low resistance
big flow theoryreducing operation costto ensure the normal work of the furnace.
2.3 de-dustingdesulfurization equipment filter material is temperature resistance
350filter material prevention corrosion.
2.4 To ensure the normal operation of desulphurization systemachieving
environmental protection standard.
2.5 Desulfurization system is running low resistance,and equipment floor space is

little.
2.6 The main equipment selection
3. System air flowFlue gas inlet temperature350 and local atmospheric pressure
conditionsdesulfurization system pipeline chose no air leakage rate, airflow is
3

80000-90000 m /h.

31 Desulfurization equipment choice


According to the original parameters and the characteristics of the furnaceand after
the management it should achieve all aspects of requirements of the environmental protection
departmentsthat,is, sulfur dioxide emissions and Ringelmann coefficient. According to the
requirement and our work experience and other examples,we decide to take the technology of
TFGD,to manage SO2, and the purpose is to effectively remove a large amount of SO2. The
specific equipment include new efficient desulfurization equipmentdehydration unit in the
back.
32 Water Pumpherewe will take engineering plastics submerged pump
feedwaterstrong corrosion resistancewith two sets.

7Desulfurization dust removal equipment principle of work


New composite efficient desulfurization equipment
Composite high efficiency low resistance desulfurization dust removal equipment is in
the original granite water film dust removal and monomer desulfurization tower and turbulent
ball tower, on the basis of three kinds of equipment to improve.It will be recombination with
these three simple equipment, so as to make up the big resistance defect for the granite water
film spiral wind and spray tower and turbulent ball tower.

Inside of the equipment added garden shape desulfurization layeran and the filter layer
devices which produced by ourselves. This filter layer is made by several small circular
support arm, and according to the characteristics of the fixed Angle, when the gas go through
the circular support arm, because of the wind movement characteristics, turn round, so the
contact surface will become bigger. And the circular surface is a lye, so gas and lye contact

surface will increase, contact time lengthen, and flue gas of sulfur of molecules and molecules
of the alkali lye can be fully in close, it is in the equipment structure to ensure the
desulfurization effect

So that the old water film is only by a cyclone principle into relying on a variety of
principle of comprehensive dust desulfurization and dehydration of new equipment, greatly
improving the sulfur removal effect, and now the new high efficiency desulfurization
equipment on modelling is not granite form, but external for steel plate, internal for corrosion
resistant material.

External is steel plate for 316 L stainless steel internal corrosion resistant materials
(divided into two layers: a layer for steel structure, the steel plate thickness, a layer of 8 mm a
layer of stainless steel 316 L, thickness of 2 mm) of several single formation, after a series of
desulfurization flue gas temperature dropped to 80-120 range.

In the installationthe equipment manufacturer firstly make every good single day
and then to the scene to organic every single according to the need for flange
connection.After combination, enter pipe installation and duct connection work. So in
equipment installation, process, it greatly reduces the time; in equipment manufacturing,
it also reduces a lot of joint.When designing, I design the tower have each two filter
layer, three distributor, each layer of distributor layer has valve, a dehydrator (vice
tower). After water separation, the clean gas go through chimney into the atmosphere.

In the above equipment structure, it divides spillway hole and cleaning eye, air inlet,
spray layer, the filter layer, water pipe, ladder stand and platform eight parts. Leave clean
window in part of the window to clean up, there are clear when open, need not when closed.

The characteristics of the equipmentreliable operation, no maintenance, easy to use,


clean simple, low operating cost.It is the best equipment,also is the most commonly used
among all kinds of boiler and furnace and smelting furnace.

RemarkPool diagram will be supplied by our company within10days after


establishment of contract.

8Operating expense
This set of equipment does not exist maintenanceobserving two to three times
every week,mainly observing the bottom water situation. Water is recycledif below the
water level,moisturizing. Temperature is not high, flue gas with water is few, so water is
on a case-by-case basis. The main cost is adding alkalinethat is desulfurization cost.
This fee should according to the factory actual situation.
9) Project Implementation Plan
Since the project contract effective dateincluding equipment design, manufacture,
installation, the plan period is 55 days.
5. Other system
Other system includes process water accident slurry system drainage fire
protection and so on.
5.1 Process water system
Due to the desulfurization system circulating fluid containing ash and particles, the
installation structure is reasonable, and we design to residue precipitation in pipe, and also use
the water flow in channel to add alkali content, like this: it can achieve dosing mixing effect.
It is also available to clean up powder sediment in the channel (very simple). So the water in
pool is very clean, no cleaning.
5.2 DrainageFire extinguishing system
a. DrainageRainwater of desulfurization island area collected by drainage ditch,
gutter inlet, inspection well and then flow to our existing drainage system.
b. Fire protectionusing chemical fire extinguisher method.

5.3 Electric System


All equipment of this system does not contain the electrical system.
5.4 Equipment heat preservation paint
Heat preservation and paint
Heat preservation range Pipeline is no need for heat preservation,but for
Anti-corrosion design.
The surface of all piping and box tank should besmear brushes anti-corrosive primer. To
not heat preservation and medium temperature less than 130 heat preservation of equipment
pipelines and accessories, support post, escalator platform to besmear brushes anticorrosive
paint, paint color should be coordination with the main project.
Corrosion Prevention
Corrosion Prevention Range All desulfurization serous or sodium alkali contact
equipment, pipeline and cell body may contact with low temperature saturated and flue gas
condensate, pipes have to take anticorrosion measures as follows:
6. After-sales service
For this project, our company promised the following items eProduct technical
service and after-sales service and measures

Equipment installation commissioning training


Our company will undertake 1 complete set of equipment installation and

debugging and the whole process of production. All equipment will be inspection and
acceptance according to relevant standards. After the acceptance, the equipment will be with
manufacturer's certificate. After reach the standard of equipment installation debugging,we
will delivery user management to use.
2

Before installationour company will provide the user the equipment installation

diagramand drawings. You can send technical person to the site for installation, serious
investigation, accurate to installation termination.

The company is responsible for equipment operation personnel training,

maintenance according to the specified time, place, we will seriously to the scene for user

training operation and management personnel And prepare relevant training maintenance
operation data, puts forward fault hair colors causes and treatment methods, combining
theory and practical operation for equipment operation training

To master relevant equipment structure principlethe most basic operation

to attempt.

First company will have training technical operation and maintenance

personnel for user, completes the training plan, schedule, method and time.

The user operation and maintenance worker training general arrange in the

period of equipment installation and operation, the time is about 5 to 7 days. It is for
management personnel to can fully understand the performance of the equipment,
maintenance and knowledge.To ensure that equipment in the commissioning period and
the future operation process, each user should master all the operation function and the
equipment failure causes and simple maintenance methods.

7Installation and construction according to the relevant state of industry standards


and reference. After the operation to the delivery of the buyer's use. To ensure achieve
GB8978-1996 <integrated emission standard> of the second kind of pollutants emission
concentration and standard.

Equipment in auxiliary for general acceptance


1. The whole system equipment in the installation is completed for debugging and
acceptance cooperating with users and local departments in the equipment And
according to the design requirements, the company worked out the project schedule,
debugging program, debugging main point and safety measures, etc.

2. According to the whole system equipment for installation check, equipment structure
layout and pipeline rout, node seal degree sealing, equipment operation has abnormal noise,

electric machine instrument performance is reasonable.If you find any unreasonable points,
pur company will be responsible for correcting until the user feel satisfied.
After-sale service
1First of all to ensure that the users supply of spare parts and to provide relevant
auxiliary material production of customers list, in order to remove the worry of user in
equipment maintenance, to ensure that the supplied goods operates continuous normal, free to
provide relevant technical data.
2All the equipment are implement three guarantees. Guarantee period is for one year,
and during the warranty period, the company will provide free repair for the product quality.
For not belong to a responsibility or the warranty equipment repair, we only take cost of
production. And we only accept costs when the time is more than warranty period
maintenance.
3For users that put forward relevant technical consulting requirements,we will reply
within 24 hours.

In the domestic, we will catch the field to solve, service item will be within

24 hours to make a decision, and 48-72 hours to the county to solve the problem.
4 The normal operation of equipment in every three months for technical
communication, taking a product quality tracking service, in order to improve the economic
benefit of the normal operation of production.

For above terms, welcome the user to supervise the implementation, and put forward
your valuable opinions and suggestions, so we can improve the product quality and after-sales
service.

Annexure - 10
Air Modeling Report

STACK EMISSION DISPERSION


MODELING OF
DHAKA SOUTHERN POWER
GENERATIONS LTD.
At
Nawabganj, Dhaka.

Prepared By:

Adroit Environment Consultants Ltd (AECL)


10/17, Iqbal Road, Mohammadpur, Dhaka-1207, Bangladesh
Tel: 8126082, 8152113, Fax: 880-2-8155542
E-Mail: aecl@dhaka.net, Web: www.aecl-bd.org
November, 2013

TABLE OF CONTENTS
1.
2.
2.1
2.2
3.
4.
5.
6.
7.
8.

INTRODUCTION
METHODOLOGY
About AERMOD View
Meteorological Condition
STANDARDS AND GUIDELINES
SOURCE PARAMETERS
BACKGROUND POLLUTANT LEVELS
MODELING RESULTS
CONCLUSION
REFERENCES

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2
2
2
3
6
6
6
7
8
32

Page 1 of 33

1. INTRODUCTION
Air Emission Dispersion modelling uses mathematical formulations to characterize the
atmospheric processes that disperse a pollutant emitted by a source. Based on emissions
and meteorological inputs, a dispersion model can be used to predict concentrations at
selected downwind receptor locations. These air quality models are used to determine
compliance with National and international Ambient Air Quality Standards.
It orders to estimate the pollutant concentration from a point source emission, USEPA
AERMOD view 8.0.5 model have been used. AERMOD view is a Gaussian plume model
that incorporates source-related factors, meteorological factors, receptors, terrain and
building downwash factors to estimate pollutant concentration from continuous point source
emission. The following report describes the prediction of emission of NO from the gas fired
engine generated power plant and its impact on ambient air quality within 5 Km radius.

2.0 METHODOLOGY
2.1

About AERMOD View

AERMOD View is a complete and powerful air dispersion modelling package that seamlessly
incorporates the popular U.S. EPA models, AERMOD, ISCST3, and ISC-PRIME into one
interface without any modifications to the model. These models are used extensively to assess pollution concentration and deposition from a wide variety of sources.
Features
Create impressive presentations of the model results with the easy and intuitive graphical
interface of AERMOD View. We can customize the project using display options such as
transparent contour shading, annotation tools, various font options, and specify compass
directions.

Specify model objects such as sources, receptors and buildings graphically.

Automatically eliminate receptors within the facility property line.

Import base maps in a variety of formats for easy visualization and source
identification.

Use the major digital elevation terrain formats - USGS DEM, NED, GTOPO30 DEM,
UK DTM, UK NTF, XYZ Files, CDED 1-degree, AutoCAD DXF.

Interpret the effects of topography by displaying the model results with 3D terrain using the powerful 3D visualization built right into the interface.

Complete building downwash analysis effectively and quickly using the necessary
tools that AERMOD View provides.

Prepare meteorological data quickly and accurately using AERMET view by the stepby-step meteorological pre-processing interface.

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Take advantage of AERMOD View's integrated post-processing with automatic contouring of results, automatic gridding, blanking, shaded contour plotting and posting
of results.

The dispersion modelling was conducted to appraise environmental impact assessment


(EIA) for the proposed HFO fired reciprocating engine power plant. In the study, the SO 2 &
NO emissions for the HFO fired engine discharged through stack was modelled to obtain
maximum possible concentration. This model was also tested in case of area source and
showed good correlation with the measured data under Bangladesh condition.
Information required for the model includes:
a) Pollutant emission rate
b) Stack exhaust exist temperature
c) Stack exhaust exist velocity flow
d) Stack diameter
e) Meteorological data
All the required information was obtained from manufacturer specification. Discharge
concentration was estimated at 500m increments from the plant up to 5 km radius.

2.2

Meteorological Condition

The Nawabganj, Dhaka area where the power plant is located has a sub-tropical climate and
is under the influence of the strong southwest or summer monsoon and weak northeast or
winter monsoon. It has been understood from last few years of air quality monitoring, the air
quality level of the area greatly influenced by the Asian monsoon. The air quality
characteristic over the area and its surrounding shows distinct seasonal variations, with high
pollution episode observed during winter, while summer has relatively cleaner ambient air.
During dry winter and part of the post-monsoon season, the strength of north, northwest
wind coming from India, Nepal and Southeast China to the Bay of Bengal through
Bangladesh may transport the air pollutants to the city. Moreover, during dry season the
wind speed is so low that the pollutants emitted from the local sources cannot travel away
from the city.
The use of site-specific meteorological data has been collected from the World Meteorological Organization (WMO) who has provided 1 Year of MM5-Preprocessed site specific Meteorological data for the period of Jan 01, 2011 to Dec 31, 2011 at Latitude: 2214'17.94"N,
Longitude: 9148'47.76"E , Time Zone: UTC +6. These data contain hourly value of wind
speed & direction, wind velocity, surface roughness, bowen ratio, albedo, temperature & reference height, precipitation rate, relative humidity, surface pressure and cloud cover over the
period mentioned above. The data then have been analysed and processed through MET
processing model AERMET View which uses Samson format to process the data and create
surface met data file & profile met data file computable to the USEPA AERMOD view dispersion model. These surface met data file & profile met data file were then used in AERMOD
view as Met input data for calculation.
The wind rose plots were drawn from the AERMET view met processor model and shows
distinct four wind directional patterns representing four seasons in a year as per air blowing
to and from (Figure 2.1 & 2.2). The mixing height in the boundary layer is one of the
important factors to assess the influence of meteorology on the dispersion of pollutants.

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Figure 2.1: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing to the project location based on Samson data processing obtained
from AERMET view.

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Figure 2.2: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing from the project location based on Samson data processing obtained
from AERMET view.

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3.0 STANDARDS AND GUIDELINES


Since HFO will be used for the proposed engine power plant, the principal air pollutant of
concern is nitrogen dioxides (NO) and Sulphur Di-oxide (SO2). The guideline value for NO
& SO2 in case of ambient air is shown in Table 3.1.
Table 3.1: Ambient air quality guideline for SO2 & NO.
Pollutants

Average period

NO2

1 hr
Annual
24 hr
Annual
24 hr
Annual

BNAAQS***

SO2
PM10

100
365
80
150
50

Standard in g/m3
WHO/IFC 2007*
200**
40**
20

US EPA
188
200

20
50

* IFC Environmental Health & Safety Guidelines 2007


** Ambient air quality standard for small combustion facility
***Bangladesh National Ambient Air Quality Standard

4.0 SOURCE PARAMETERS


The exhaust specifications and stack parameters for the proposed HFO generator is used as
input to USEPA AERMOD view model. The model calculates the values of 3 HFO
generators as point source of PM10, SO 2 & NO2 emissions. The parameters and
corresponding values are summarized in Table 4.1.
Table 4.1: The exhaust specifications and stack parameters (for each stack)

Parameters
Stack height (m)
Stack inside diameter (m)
Stack exit velocity (m/s)
Exhaust temperature (K)
Exhaust flow rate (m3/sec)
NOx emission rate as NO2 (gm/sec)
SO2 emission rate (gm/sec)
PM emission rate (gm/sec)
Ambient temperature (K)

5.0

Values
32
4.5
(195+273) = 468
14.22
10.01
49.33
7.64
273

BACKGROUND POLLUTANT LEVELS

This information was needed for the purpose of estimating the worst-case combined impact
of the proposed power plant and existing pollutant sources, which can then be compared to
the air quality objectives. There was no long-term data available for the area of concern. A
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limited monitoring was conducted by AECL (sampling & analysis has been done by AECL
Lab team on 03/11/2013 to 05/11/2013) for obtaining 24-hour average of pollutant
concentrations at different distances from the project site. The data are given in Table 5.1.
Table 5.1: The average concentrations at different distances
SN

Description

PM2.5

Method of analysis

Gravimetric

Ambient Air Pollution Concentration in micro gram/cubic meter.


PM10
SPM
SO2
NOX
CO
Jacob and
Gravimetric Gravimetric West-Geake
Indicator Tube
Hochheiser
24
24
24
24
24

Test Duration (Hours)

24

Bangladesh (DoE) Standard for ambient Air

65

150

200

365

WHO /World Bank Standard


Test result (Concentration present) in Project
West-North corner near boundary area.
(Date :03/11/2013)
Test result (Concentration present) in Project
West-North corner near boundary area.
(Date :04/11/2013)
Test result (Concentration present) in Project
West-North corner near boundary area.
(Date :05/11/2013)

25

50

NF

20

27

67

143

12

100

10000
NF

21

170

31

77

159

14

26

180

25

65

147

17

23

190

Remarks

Pollution source from normal activities

Note:

1. Fine Particulate Matter (PM2.5).


2. Respirable Dust Content (PM10).
3. Suspended Particulate Matter (SPM).
4. Oxides of Nitrogen (NOX).
5. Sulphur Di-Oxide (SO2).
6. Carbone Mono-Oxide (CO).
The weather was sunny and the wind direction was from the north-west to south-east corner.

6.0

MODELING RESULTS

The modelling was conducted for the 3 individual engines releasing gaseous
emission as point source with simple terrain using USEPA AERMOD view version
8.0.5 model. The model assumes the stack tip downwash with receptors on flat
terrain and no flagpole receptor heights. The PM10, NO2 & SO2 concentration
contour have been analysed with 500 m interval with a radius of 5000m from the
point source.
NO2 concentration:

The NO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of NO 2 (30-50 g/m3) has been
predicted at a radius of 200mnorth & south and 1000m north & south to the project.
The concentrations are found below 10-30 g/m3 within 1000m north & south and
around up to 5000 to the other sides. The maximum annual concentration of NO2
has been detected as 3-5 g/m3 at 500m around the project side and the
concentrations are within 0.5-3 g/m3 on the either sides up to 5000m from the
project.
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SO2 concentration:

The SO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of SO2 (100-300 g/m3 ) has been
predicted at a radius of 500m north & south and 2000m northwest & northeast to the
project, whereas the concentrations are within 50-100 g/m3 at a radius of 5001000m north & south and up to 5000m to the other sides. The maximum annual
concentration of SO2 has been detected as 20-50 g/m3 at 500m around the project
site, whereas the concentrations are within 5-20 g/m3 on the either sides at around
1000 m north & south and up to 5000m at the other sides to the project.
PM10 concentration:

The PM10 concentration contour of 24 hour and annual average of have been
analyzed. The maximum of 24 hour concentration of PM10 (10-40 g/m3) has been
predicted at a radius of 200-500m north & south and up to 5000m east & west to the
project site. The concentrations are found below 10 g/m3 at the other sides of the
project site beyond 500m. The maximum annual concentration of PM10 has been
detected as 3-8 g/m3 at 500m around the project side and the concentrations are
below 3 g/m3 at all the sides which is coming down to 0.3 g/m3 from 500m 5000m
surrounding the project.

7.0 CONCLUSION
NO2 Concentration:
There is no IFC/WHO and Bangladesh standard set for 24 hour concentration for
NOx. The maximum yearly concentration of NOx have been detected (max 5 g/m3)
well below the IFC/WHO and Bangladesh standard at all sides at any radius around
the project.
SO2 Concentration:
There is no IFC/WHO annual standard set for SO 2 for ambient air quality, the 24
hour concentration of SO2 have been found (100-300 g/m3 ) above the IFC/WHO
standard (20 g/m3) but below the Bangladesh standard (24 hour average 365 g/m3
and annual average 80 g/m3) at all sides of the proposed project. The plant would
have a FGD, in which the emission level for SO2 will further be reduced by 90% and
thus will come down to 10-30 g/m3 (24 hour average) and 0.20-0.50 g/m3 (annual
average) which all will comply the both the IFC/WB standard and Bangladesh
NAAQS standard.
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PM10 Concentration
The IFC/WHO and Bangladesh standards for 24 hour PM10 concentrations are (50
g/m3 and 150 g/m3 respectively) and annual concentrations (max 20 g/m3 and 50
g/m3 respectively). The 24 hour and annual PM10 concentrations have been found
below Bangladesh and IFC/WB standard at all the sides of the project. Further, on
installing FGD, it will also substantially reduce PM emission (>50%) as it uses a wet
scrubbing process.

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Figure 6.1: Emission contour map showing the NOx concentration (24 hour average) at 5000m surrounding the project location

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Figure 6.2: Emission contour map showing the NOx concentration (Annual average) at 5000m surrounding the project location

AECL/AEDM/DSPGL/2013

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Figure 6.3: Emission contour map showing the SO2 concentration (24 hour average) at 5000m surrounding the project location

AECL/AEDM/DSPGL/2013

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Figure 6.4: Emission contour map showing the SO2 concentration (Annual average) at 5000m surrounding the project location

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Figure 6.5: Emission contour map showing the PM10 concentration (24 hour average) at 5000m surrounding the project location

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Figure 6.6: Emission contour map showing the PM10 concentration (Annual average) at 5000m surrounding the project location

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The following are the emission concentration plots in different directions of the power project at 24 hour and annual average of NO2
concentration:

Figure 6.7a: NO2 Emission concentration plots (24 hour average) at 5000m east to the project location

AECL/AEDM/DSPGL/2013

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Figure 6.7b: NO2 Emission concentration plots (24 hour average) at 5000m north to the project location

AECL/AEDM/DSPGL/2013

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Figure 6.7c: NO2 Emission concentration plots (24 hour average) at 5000m south to the project location

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Figure 6.7d: NO2 Emission concentration plots (24 hour average) at 5000m west to the project location

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Figure 6.8a: NO2 Emission concentration plots (Annual average) at 5000m east to the project location

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Figure 6.8b: NO2 Emission concentration plots (annual average) at 5000m north to the project location

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Figure 6.8c: NO2 Emission concentration plots (Annual average) at 5000m south to the project location

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Figure 6.8d: NO2 Emission concentration plots (Annual average) at 5000m west to the project location

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Figure 6.9a: SO2 Emission concentration plots (24 hour average) at 5000m east to the project location

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Figure 6.9b: SO2 Emission concentration plots (24 hour average) at 5000m north to the project location

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Figure 6.9c: SO2 Emission concentration plots (24 hour average) at 5000m south to the project location

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Figure 6.9d: SO2 Emission concentration plots (24 hour average) at 5000m west to the project location

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Figure 6.10a: SO2 Emission concentration plots (annual average) at 5000m east to the project location

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Figure 6.10b: SO2 Emission concentration plots (annual average) at 5000m north to the project location

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Figure 6.10c: SO2 Emission concentration plots (annual average) at 5000m south to the project location

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Figure 6.10d: SO2 Emission concentration plots (annual average) at 5000m west to the project location

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8.

REFERENCES

1. Screening Procedures for Estimating the Air Quality Impact of Stationary Sources,
Revised, EPA-450 R-92-019.
2. Bilkis A. Begum, Naima A. Khan, M. Khabir Uddin and Swapan K. Biswas,
.Characteristics and short-range transport of particulate matter from Dhaka-Aricha highway..
J.of Bangladesh Chemical Society, 22(1), 2009, 18-34.
3.Bilkis A. Begum, Swapan K. Biswas, Andreas Markwitz and Philip K Hopke, .Identification
of sources of fine and coarse particulate matter in Dhaka Bangladesh.. Aerosol and Air
Quality Research, 10, 2010, 345-353.
4. IFC Environmental Health and Safety Guidelines. 2007
5. Air/Superfund National Technical Guidance Study Series, Volume 4: Guidance for Ambient Air Monitoring at Superfund Sites, Revised EPA Number: 451R93007, NTIS number
PB93-199214
6. Jindal, M., Heinold, D., 1991, "Development of Particulate Scavenging Coefficients to
Model Wet Deposition from Industrial Combustion Sources". Paper 91-59.7, 84th Annual
Meeting Exhibition of AWMA, Vancouver, BC, June 16-21.
7. Ontario Ministry of the Environment, July 2005. Air Dispersion Modelling Guideline for Ontario, Version 1.0. PIBS#5165e. Ontario Ministry of the Environment, Toronto, Ontario.
8. U.S. Environmental Protection Agency, 1985. Guideline for Determination of Good Engineering Practice Stack Height (Technical Support Document for the Stack Height Regulations). Revised EPA-450/4-80-023R. U.S. Environmental Protection Agency, Research Triangle Park, North Carolina 27711.
9. U.S. Environmental Protection Agency, 1986. Users Guide to the Building Profile Input
Program. Revised EPA-454/R-93-038. U. S. Environmental Protection Agency, Research
Triangle Park, NC.
10. U. S. Environmental Protection Agency, 1987. Guidelines on Air Quality Models (Revised) and Supplement A. EPA-450/2-78-027R. U. S. Environmental Protection Agency, Research Triangle Park, NC.

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Annexure - 11
Noise Modeling Report

Noise modeling of 55 MW Power Project of


Dhaka Southern Power Generations Ltd.

Table of Contents

1.
2.
3.
4.
5.
6.

Noise Pollution
Impact on Noise Quality
Noise Modeling input data
Noise Modeling
Noise Modeling Result
Resultant noise emission

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1.0 Noise pollution


The word "noise" comes from the Latin word "nausea" meaning Sea sickness. Noise
is among the most pervasive pollutants today. Noise pollution can be caused by
many sources including highways, vehicles, factories, engines, machine, aircraft,
helicopters, industrial development and construction work. Noise negatively affects
human health and well-being. Problems related to noise include stress, sleep loss,
distraction, and a general reduction in the quality of life. Noise pollution can be also
harmful to animals. High enough levels of noise pollution may interfere with the
natural cycles of animals. Noises are irregular and disordered vibrations including all
possible frequencies. The intensity of a sound I can be expressed in decibels with
the standard equation:
L=10 log(I/I0)
where I0 is the quietest sound most people can hear, the threshold of hearing 1012Wm-2. When the ratio is between two field strength (so that the power being
transmitted is proportional to the square of the pressure, the formula is:
LdB=10 log[p2/(p0)2]
The decibel unit is often used in acoustics to quantify sound levels relative to some 0
dB reference. The reference may be defined as a sound pressure level (SPL),
commonly 20 micropascals. The reference sound pressure (corresponding to a
sound pressure level of 0 dB) can also be defined as the sound pressure at the
threshold of human hearing, which is conventionally taken to be 20 micropascals. It
can therefore be seen that a ratio expressed in decibels. A-weighted decibels are
abbreviated dB(A) . When acoustic measurements are being referred to, then the
units used will be dB SPL (sound pressure level) referenced to 20 micropascals = 0
dB SPL.
The frequency range of sound audible to humans is approximately between 20 and
20,000 Hz. The amplitude range of sound for humans has a lower limit of 0dB, called
the threshold of hearing. Sound is technically at its upper limit at 194.09 dB. Sounds
begin to do damage to ears at 85 dB and sounds above approximately 130 dB.
The intensity of two sounds L1 and L2 can be added in decibels with the standard
equation:
LdB=10 log[(p1/p0)2+[(p2/p0)2]
and then,
LdB=10 log[10L1/10+ 10L2/10]
In this way, decibels from two different sources can be added. CUSTIC Software will
consider this method of calculation.

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2.0 Impact on Noise Quality


The main sources of noise during operations of the power plant will be from the 3
exhaust stack of the HFO engine generator. The generators will be fitted with a
silencer prior to disperse the emission through stack. The power house building will
adopt modern building design and the use of sound absorbing materials to minimize
noise and vibration from the powerhouse.
A. Engine room noise:
The generator room will have internal noise level of around 107 dBA at 1m distance
from each reciprocating engine and the noise level at the steam turbine unit is 90
dBA, the combined noise effect from the 3 engines and turbines can be found by
applying the formula of (L = 10. Log10 (10L1/10 + 10L2/10) dBA, in which the
equivalent noise will be 112 dBA from all engines & turbines, which will be minimized
by sophisticated acoustic power house building design so as to minimize the noise
emission up to standard. The generators and turbines are enclosed in buildings
acoustically designed, providing Styrofoam filler of 100 mm width in between 150
mm thick brick walls both side (sandwich type).
The Styrofoam filter and brick wall will absorb noise as following:
Material

Thickness,
mm
100

Approximated noise
absorption capacity, dBA
90

150

40
90

Styrofoam (Acrylic -PolyMethyl-MetaAcrylate (PMMA)


Brick with or without plaster
Total Equivalent noise

It is estimated that the noise abatement measures of the power house building will
be capable to absorb around 90 dBA noise from the engine room, but the maximum
engine room noise is around 112 dBA near the generators & steam turbine, the
further noise emission simulation from the power house building will be determined
by the modelling calculation.
B. External noise emission:
The individual reciprocating engine stack will emit a noise level of 65 dBA after
providing the silencer (25 dBA abatement from the steam turbine exhaust). Further
noise emission simulation from the stack will be determined by the modelling
calculation.
3. Noise Modeling input Data:
The following input data has been used for the modeling:
AECL/NM/DSPGL/2013

Page 3 of 6

A. Internal point source


Equivalent Noise Power: 112 dBA (from 3 engines and turbines)
Total External surface area: 1640 sq.m
Noise insulation : 90 dBA
Engine room noise: 107 dBA
Turbine Noise : 90 dBA

B. External point source


Noise Power: 65 dBA (Single stack point)
Total stack: 3 Numbers
Stack height : 32m
Terrain: Flat Terrain without sound attenuation
Height of noise calculation: Surface height
4. Noise Modeling
Noise Modeling Software: CUSTIC 3.2
Canarina CUSTIC 3.2 software for noise pollution modelling is used for the
assessment of the noise propagation of this power project. The CUSTIC Software
allows us to create robust and useful numeric simulations that fully make use of the
graphical user interface, with a certain security that the software CUSTIC 3.2 is one
of the best tool, to carry out numeric simulations of noise pollution.
The cumulative impact from the stationary noise sources at proposed project site has
been predicted using the above model. It was found that the ambient noise is higher
than predicted levels therefore, due to the masking effect, an increase is not
expected.
5. Noise Modeling Results
A. Internal Noise Modelling result
At 112 dBA equivalent noise output from the 3 engines and turbines and equivalent
noise absorption of 90 dBA by the Styrofoam and brick wall, the resultant noise
emission simulation has been done by the model and the predicted noise output is
as below:
Radius, m
Output Sound power level
in dBA

AECL/NM/DSPGL/2013

30
25.03

50
100
20.85 16.89

200
12.52

300
8.34

400
4.17

Page 4 of 6

Fig 1: Plot of output noise power level in dBA vs Radius in meter (Internal Engine room noise)

B. External Noise Modelling result


At 65 dB noise output from the each stack after silencer, the resultant noise emission
simulation has been done by the model and the predicted noise output is as below:
Radius, m
Output Sound power level
in dBA

AECL/NM/DSPGL/2013

30
27.70

50
100
23.09 18.48

200
13.86

300
9.24

400
4.62

Page 5 of 6

Fig 2: Plot of output noise power level in dB vs Radius in meter (external stack noise)

6. Resultant noise emission from External and Internal Sources


The resultant noise emission from the internal and external sources of the power
plant has been calculated by the equivalent noise summation formula and the
resultant noise has been given below:

Radius, m
Output Sound power level in
dBA (Internal noise)
Output Sound power level in
dBA (External noise)
Equivalent Noise emission
(internal & external)

AECL/NM/DSPGL/2013

30
25.03

50
100
20.85 16.89

200
12.52

300
8.34

400
4.17

27.70

23.09 18.48

13.86

9.24

4.62

29.58

25.12 20.77

16.25

11.82

7.41

Page 6 of 6

Annexure - 12
NOx & SO2 Calculation

Exhaust flow rate calculation:


Exhaust Flow rate: 127 Tons/hour at 573 OK
The density of air at 300 OK is 1.3 kg/cu.m
The density of air at 598 OK is 2.48 kg/cu.m (Using V1/T1 = V2/T2)
So, the Exhaust flow rate is 51209 m 3/hr at 573 OK = 14.22 m3/sec

NOx emission rate calculation:


1. Nox emission concentration: 1480 mg/Nm3
2. Exhaust flow rate: 51209 m3/hr
3. Stack temperature: 300 0C = 300+273 = 573 OK
Using V1/T1 = V2/T2
Where V1 = 51209 m3/hr, T1 = 573 OK, V2 =? & T2 = 273 OK
Using the formula: V2 = 24398 Nm3/hr = 6.77 Nm3/sec
Now the NOx emission rate is 1480 x 6.77 = 10019.6 mg/sec = 10.01 gm/sec

SO2 emission rate calculation:


Fuel Consumption = 68800 tons/year
Sulphur content in the fuel = 3.4%
Total Sulphur content per year = 68800 x 3.4/100 = 2339 tons/year
Total SO2 emission rate per year = 4678 tons/year = 148 gm/sec
Total SO2 emission rate per year through one stack = 148/3 = 49.33 gm/sec

Annexure - 13
Land lease Agreement

Annexure - 14
Ambient Noise Quality Test Report

Annexure - 15
Ambient Air Quality Test Report

Annexure - 16
Site Clearance Certificate

Annexure - 17
Electrical Interconnection for power
Evacuation

Annexure - 18
Elevation Survey Report of the Site

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Annexure - 19
Fuel Transmission Line

Annexure - 20
General Arrangement of Pontoon

Annexure - 21
Contour Map of River & Road Site