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24 MW HFO Plan
24 MW HFO Plan
Basic Description
y MAN Diesel (HFO) 18V28/32 Containerized Generator Sets
y Siemens Control and Instrumentation
y Alfa Laval fuel processing equipment
y Chubb fire protection
Introduction to MAN 18V28/32S
The MAN 18V28/32S Generator Set is a well-proven m edium-speed unit providing over 4 M W at
ISO conditions. It is conservatively rated and offers exceptional reliability and operating economics.
(see the attached)
The prime mover for the Generating Sets is a MAN 28 cm bore Medium -Speed Diesel Engine with
18 cylinders in VEE configuration. The Engine is turbochar ged and intercooled and is
conservatively rated; both in terms of its piston speed and its operational pressures and temperatures.
The Engine runs at 750 rev/m in, and is suitable for continuous base load operation on HFO (Heavy
Fuel Oil) with viscosity up to 700 centistokes (cSt) at 50 deg C and with a sulfur content up to 3.5%.
Engine Jacket and Fuel Oil Hea ting Systems enable the Engines to operate without delay on HFO,
reducing the consumption of expensive Light Diesel Fuel to an absolute minimum.
Integral Fuel Injector C ooling Systems are provi ded, preventing the build up of fuel deposits and
cold corrosion on the injector nozzle tips.
This solution is constructed so that groups of three (3) G enerator Sets share fueling and other
auxiliary systems to reduce both set up costs and installation time.
These “M3” Plants can be linked together to create Power Plants from 12 to 72 MW.
Acoustic Enclosures
Each Gener ating Set is insta lled w ithin a pu rpose designe d and built enclosur e th at achieves a
reduction in Plant noise levels by up to 50 db(A).
The Enclosures are of sufficient size to enable al l Plant servicing and m ajor overhauls to be carried
out within the protected environment of the Enclosure.
The Enclosure is designed to be transportable within ISO 40 ft c ontainers and then easily
constructed at the generation site piece by piece.
Electrical Module
The primary function of this Module is to s ynchronize the outputs from the individual Generating
Sets. To provide the Plant output to a Power Transformer or to Switchgear.
To provide auxiliary supplies throughout the Plant and to provide a Black-Start capability.
Switchgear
HFO Fuel Tank
Based upon a standard ISO 40-foot c ontainer, this Module provides suf ficient fuel to operate each
group of three MAN Generating Sets at maximum continuous output for approximately 24 hours.
A number of Tanks could be grouped together and stacked to increase fuel storage capacity.
Constructed with an integral bund wall to contain spills, and with integral h eating coils, an HFO
Buffer Tank is located adjacent to each group of Generating Sets.
A Local Pumping Chamber with duty/standby units transfers the f uel oil dir ectly to th e HFO
Treatment Module.
Water Pumping System
The Engines have clos ed-circuit air -blast Radiat ors and water consum ption is f or initial f ill and
occasional make-up only.
The HFO and Lube Oil centrifuges use a sm all amount of water to maintain a gravity seal in the
centrifuge bowls, but this water can be treated and re-used if required.
Fire Pumps complying with current NFPA standards, and a Reverse Osmosis unit providing process
and drinking quality water for the plant and domestic facilities are Contained in Module 7.
Multi-function Skids
The m ulti-function skid installed be tween th e E ngine and the end wall of the a coustic Enclosu re
contains the Engine starting air supplies, Air Compressors, Fuel Changeover System , Injector
Cooling Module, Dosing System for Engine coo ling water , Lube Oil Centrifuges, and the
Emergency Fuel Shut-Off System.
Modular Radiators
The Engine Cooling Radiators are a closed circuit, fan cooled design, with zero evaporation losses.
They are suitable for continuous operation in high ambient and high humidity conditions.
Fan operation is controlled therm ostatically to optim ize operational efficiency, and pipe work and
control cabling are already fitted into the Modules.
The vulnerable soft alloys necessary for ef ficient cooling are encased in a robust space-fram e for
transport.
The frame then becomes the Radiator support stand when the unit is mounted adjacent to the Engine
Enclosure
HFO Module
Based upon a standard ISO 40-foot container , th is Module will continuously treat HFO with
viscosities ranging up to 380 cen tistokes at 50 deg C, and supply it to each group of three MAN
Generating Sets.
The Module Equipm ent com prises the latest fuel treatm ent technology , including Alfa Laval
duty/standby centrifuge filters and fuel forwarding units.
Conservatively rated transfer a nd circulating Pumps, pre and pos t centrifuge Treatment Tanks, and
Fuel Oil Heating Units are an integral part of this Module.
The Module design is adequate for the treatment of HFO at ambient temperatures down to 10 deg C
using either electric heaters or high temperature hot water produced by Exhaust Gas Economizers.
Individually pumped ring mains supply the treated HFO to the MAN Generating Sets.
An individual Generating Set can be taken out of service for scheduled m aintenance without
impacting upon the security or reliability of the remaining running units.
Exhaust System
Exhaust gas from the Engines is routed through an economizer to achieve high operating efficiency.
The Silencer achieves approximately 45 bB(A) reduction in noise levels and the height of the S tack
can be adjusted to meet gas dispersion requirements.
Control Centre
Based upon an ISO 40-foot Contain er, this Module provides the air-conditioned heart of the Power
Plant.
All generating operations are controlled from t his point, including ener gy dispatch to the power
purchaser, data logging and trend analysis of all key operating functions, communications with local
and national control centers, and starting and stopping of the individual Generating Sets.
The offered Six (6) units of MAN 18V28/32S are brand new and manufactured in year 2009. All units
were never used for any commercial operation and are with full OEM warranty.
Control system was designed by Regulateurs Europa and set of Siemens make SCADA control
equipment.
Type and make of the components of the switchgear and circuit breakers
One Containerized 33KV Switchgear with two incoming feeders (each 1250A) from two 11/33KV
Transformers and 6 outgoing feeders of 1250A each.
All 6 circuit breakers will have Copper bus. Besides that it will also include 2 Transformer Protection
Panels, Grid Protection Panel, Synchronizing Panel, Instrumentation and HT Cabling (Copper).
We have considered 10 meters length each between Transformers and 33KV Switchgear.
Year of Manufacture
The year of manufacture of 6 MAN engines and Balance of Plant is 2008/2009.
Fuel Consumption at full load
Please see fuel consumption at varying ambient temperatures and corresponding loads including full
load per train (3 units, 12MW ISO). We have assumed 100m elevation and a calorific value of fuel at
42,700 kJ/kg:
Temp (ºC) Plant net output capacity (MW) at 11kV Plant net fuel efficiency/consumption
taking into account the site parasitic (g/kWh) at 11kV taking into account
losses. the site parasitic losses.
20 ºC 11.60 MW 216.4 g/kWh
25 ºC 11.60 MW 217.8 g/kWh
30 ºC 11.60 MW 219.2 g/kWh
35 ºC 11.60 MW 220.6 g/kWh
40 ºC 11.26 MW 222.3 g/kWh
45 ºC 10.82 MW 224.2 g/kWh
50 ºC 10.41 MW 226.1 g/kWh
Fuel Tanks
The HFO tank per 3 unit train is included as per the scope sent earlier. The capacity of each HFO
tank/container will cater HFO fuel for 3 engines for 24 hours operation.
Dimensions:
The plant consists of two 12 MW blocks (3 x 4 MW). They can be used together and independently.
Each 12MW self-contained block (3 units) requires a site with dimensions 55m x 35m.
The layout/position of each component is fixed within the design and cannot be altered being
containerized.
The position of the two 12MW blocks with respect to each other is flexible.
Within the generic layout drawing the 24MW power plant occupies a site with approx. 18,000 meters
square (dimensions: 140m x 130m).
This includes a bulk HFO storage tank and HT electrical switch yard (in your case 33KV) as well as a
generous access/perimeter road and perimeter fence buffer.
ERECTION & COMMISSIONING
All items and systems indicated below including piping, cabling and accessories (containerized) will be
erected and prepared for commissioning.
All commissioning work will be done by erection team and their qualified engineers.