Professional Documents
Culture Documents
Seminar Report of
Degree of B.TECH
(MECHANICAL ENGINEERING)
(SESSION 2021-22)
APRIL 2022
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CERTIFICATE
Dr. M A SALODA
SEMINAR GUIDE
DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF TECHNOLOGY AND ENGINEERING
MPUAT, UDAIPUR
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ACKNOWLEDGEMENT
First and foremost, I wish to record our sincere gratitude to Dr. B L SALVI
(Head of Department) for this seminar on the topic “DIESEL POWER
PLANTS”.
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ABSTRACT
Here in this report, we are discussing how diesel power plants play a
major role in power generation in India. Also I have given
information about how it works and power generation process takes
place in a power station
Diesel engines play a critical role in stabilizing the electricity grid and
provision of emergence and peak load supply. This report analyzed
the role of diesel power plants in generation and supply of grid
electricity with performance analysis of Diesel power plant. The
study established that the main challenges of diesel power
generation is low plant use factor, low capacity factor, low plant
availability and high cost of operation and maintenance and hence
high cost of power. Long procurement procedures and low technical
capacity are responsible for the high plant downtime and hence low
availability while high operation and maintenance costs including
cost of heavy fuel oil are the main reasons for high electricity cost.
The study recommends cogeneration, contract management and
efficient procurement system for spares.
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INDEX
2. Acknowledgement 3
3. Abstract 4
4. List of figures and tables 6
5. Introduction 7
6. Case Studies
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Case study
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7. Summary 28
8. Reference 29
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LIST OF FIGURES
LIST OF TABLES
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INTRODUCTION
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Since a conventional synchronous generator is used, special attention
to frequency and synchronization is required
The diesel power uses a diesel engine to rotate alternators and
produce electrical energy. The diesel engine is used as a prime mover
and this power plant is known as a diesel power plant. Due to the
combustion of diesel, rotational energy is generated. The alternator is
connected with the same shaft of the diesel engine. And the alternator
is used to convert the rotational energy of the diesel engine into
electrical energy.
In most cases, the diesel power plant is used to generate electrical
energy for small-scale production and at the load end. When the grid
power is not available, the diesel engine is used to supply load in
emergency conditions.
Generally, the capacity of diesel power plants is between 2 to 50 MW
is used in central power plants to meet peak demand in steam power
plants and hydroelectric power plants. But nowadays, due to the high
cost of fuel, diesel engines are not used for such applications.
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Schematic Diagram of Diesel Power Plant
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Different components or system used in a diesel power
plant is as listed below.
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Diesel engine
Air intake system
Exhaust system
Cooling water system
Fuel supply system
Lubrication system
Diesel engine starting system
Diesel Engine
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It is the main components used in diesel electric power plant for
developing mechanical power. This mechanical power we use to
run the generator & produce electrical energy. For producing the
electrical energy the diesel engine is mechanically coupled to
generator. When the diesel fuel burning inside the engine, its start
to produce a mechanical power. The combustion of diesel fuel
produces increased temperature & pressure inside the engine.
Due to this pressure gases are formed, this gas pushes the piston
inside the diesel engine, and then mechanical power is produced.
With the use of this mechanical power the shaft of diesel engine
starts rotating.
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It consists of Fuel Storage Tank, Fuel Filter or Strainer, Fuel
Transfer Pump, Day Tank, Heaters & Connecting Pipes. First up all
with the help of transportation facility available (road, rail etc.)
the diesel fuel stored in storage tank. Then this diesel fuel transfer
to day tank, the function of day tank is how much quantity of
diesel required for 24 hours is store. If the day tank is full or
overflow occurs, then excessive diesel returned to storage tank.
The filter or strainer is used to purify diesel. With the help of fuel
transfer pump the diesel is transfer to day tank.
Engine Air-Intake System:
This System includes air filters, air tank, compressor & connecting
pipes. The air filters are used to supply the fresh air to diesel
engine for the purpose of combustion. Engine required fresh air
because, if dust particles in the air entered into the engine will
cause disastrous effect to valve, cylinder & pistons. The
compressor or Supercharger is used to increase pressure of the air
supplied to the engine. This will helps to increase the output
power.
Engine Exhaust System:
These systems consist of silencers & connecting ducts. As the
temperature of the exhaust gases is sufficiently high, it is used for
heating the fuel oil or air supplied to the diesel engine. The
exhaust gas is removed from engine, to the atmosphere by means
of an exhaust system. A silencer is normally used in this system to
reduce noise level of the engine.
Engine Cooling System:
The Diesel Engine Cooling System Consist of coolant pumps, water
cooling towers or spray pond, water treatment or filtration plant
& Connecting Pipe Works. The heat produced due to internal
combustion, drives the engine. But some parts of this heat raise
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the temperature of different parts of the engine. High
temperature may cause permanent damage to the machine.
Hence, it is essential to maintain the overall temperature of the
engine to a tolerable level. Cooling system of diesel power station
does exactly so. The cooling system is required to carry heat from
diesel engine to keep its temperature within safe limits. The water
pump circulates water to cylinder of diesel engine to carry away
the heat. The cooling tower is used for the same water reused.
The cooling system requires a water source, water pump and
cooling towers. The pump circulates water through cylinder and
head jacket. The water takes away heat from the engine and it
becomes hot. The hot water is cooled by cooling towers and is re-
circulated for cooling.
The cooling system can be classified into two types :
1. Open Cooling System: A Plant near the river may utilize the
river water for cooling & discharging again the hot water into
river. This type of cooling system is known as open cooling
system
2. Closed Cooling System: The Cooling Water is circulated again
& again and only water lost due to leakage, evaporation etc. is
made up by taking make up water from supply source.
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lubricating oil is delivered to the different points of the machine
where lubrication is required the oil cooler is provided in the
system to keep the temperature of the lubricating oil as low as
possible. It is then cooled through heat exchanger by means of
cold water and then it is fed to the engine.
Engine Starting System: The function of starting system is to
start the engine form stand still or cold conditions by supplying
compressed air. For starting a diesel engine, initial rotation of the
engine shaft is required. Until the firing start and the unit runs
with its own power. For small DG set, the initial rotation of the
shaft is provided by handles but for large diesel power station.
Compressed air is made for starting.
This system includes storage compressed air tank, self starter,
auxiliary engines & electrical motors (battery) etc.
1. Starting of Small Engine: Small sets or small capacity of diesel
engines are started manually.
2. Starting with the help of Auxiliary Engine: When it is started
by auxiliary engine, the auxiliary engine is disengaged by the main
engine & started by hand. When it is warmed up, it is geared with
the main engine so that it will start to rotate. After that within,
few seconds auxiliary engine disengaging.
3. Starting with the help of batteries: To start the electrical
motor batteries are used, the motor is geared with diesel engine,
it will start rotating with the motor & will start in few seconds &
as it picks up the speed the motor gets disengaged automatically.
In some cases the motor works as a generator, this will further
helps to charge the batteries.
4. Starting with the help of compressed air: A large capacity
(above 75kW) capacity diesel engines are started with the help of
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compressed air. Diesel engines are started with the help of
compressed air following procedure adopted:
1. First up all open the compressed air valve, then starting
lever operated.
2. First up all air should be cut off in first combustion. Then
open ventilating valve. Start the engine after two or three
revolutions
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2. Compression: This stroke begins at B.D.C, or just at the end of
the suction stroke, and ends at T.D.C. In this stroke the piston
compresses the air-fuel mixture in preparation for ignition
during the power stroke (below). Both the intake and exhaust
valves are closed during this stage.
3. Power: This is the start of the second revolution of the four
stroke cycle. At this point the crankshaft has completed a full
180° revolution. While the piston is at T.D.C. (the end of the
compression stroke) the compressed air-fuel mixture is ignited
by a spark plug (in a gasoline engine) or by heat generated by
high compression (diesel engines), forcefully returning the
piston to B.D.C. This stroke produces mechanical work from the
engine to turn the crankshaft.
4. Exhaust: During the exhaust stroke, the piston once again
returns to T.D.C from B.D.C while the exhaust valve is open.
This action expels the spent air-fuel mixture through the
exhaust valve
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Maintenance of Diesel Electric Power Plant
At the time of diesel engine or diesel electric power plant,
following points are considered during maintenance period.
a) To maintain the operating condition of diesel engine at every
half hour.
b) To maintain the correct record of the instrument reading in
log sheet.
c) To maintain the record of instrument temperature, pressure,
electrical load, flow etc.
d) To check the level of fuel oil periodically.
e) Filterized the fuel and remove unwanted impurities.
f) Clean the fuel tank at regular interval.
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3. Labour: Large capacity diesel power plant requires several
labours.
4. Availability of water: The diesel power plant requires water for
cooling purposes.
5. Future expansion: There is some extra land available for future
expansion.
6. Availability of fuel: This plant requires a high volume of fuel
(diesel). So, a site should be selected where fuel is available
easily.
7. Distance from the populated area: The operation of a diesel
engine pollutes nearby areas. Hence, the plant must be located
at a far distance from the human being.
8. Distance from load centre: To avoid transmission loss, the site
should be selected near the load centre.
9. Application of Diesel Power Plants.
2. Peak load plant : The diesel power plant is used with thermal
power plant and hydroelectric power plant to meet peak
demand. It reduces the per-unit cost of power generation. It
can easily start and stop with demand and varying with load
variation.
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3. Emergency plant : The diesel engine can be used as an
emergency plant. When the power of the grid is not available,
the diesel engine is used as a backup plant for emergency
conditions
4. Mobile plant : The small and medium capacity of the diesel
power plant can be fixed on a truck or trailer. This plant can be
used as a mobile power plant and we can take this plant to
supply where grid power is not available. This plant is also used
as an emergency plant while power failure.
5. Stand by unit : This plant can be used as a stand-by unit with a
hydroelectric power plant. When the water is not available
sufficiently in the hydro power plant, to meet power demand
the diesel power plant operates parallel with the hydropower
plant.
6. Power plant for small industries : This plant can be used to run
a small industry for short periods where the reliability of power
is essential throughout the day.
7. Nursery station : In some areas where a grid is not available or
any developing area where does not have enough load to
connect with a grid, the diesel power plant is used as a
temporary solution to supply power. And remove when the
grid is connected.
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Advantages & Disadvantages of Diesel Power Plant:
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5. The cost of lubrication is generally high.
CASE STUDY
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power. Diesel generators are commonly used to fill these deficit. The
global energy consumption as in 2012 stood at 104,426 TWhr with
fossil fuel being the largest contributor. Electricity accounted for
about 18.1% of the total energy consumption in 2012. In 2013 the
world electricity generation was about 23,322 TWhr of which 41.3%
was from coal, 21.7% from natural gas, 16.3% from hydro, 10.6%
from nuclear, 4.4% from oil and 5.7% from renewable sources such
as geothermal, wind and solar. In 2004, between 10% and 15% of
global electricity production, came from diesel engine power
generation whose main application globally is use as standby and
emergency applications by hospitals, airports, hotels, industry, and
most utilities that need reliable power throughout
The continued use of diesel power plants for electricity generation is
often prompted by seasonal variability of hydropower due to
drought. Due to this, diesel power plants are still used to supply peak
and base load electricity for public grids in many developing
countries.
This study examines diesel power generation to establish its
feasibility in supplying reliable and cost-effective electricity to the
grid by carrying out a performance analysis of Kipevu I power station
in Kenya to determine challenges facing diesel engine power
generation for grid electricity. `
Problem Statement
Energy is a critical ingredient for sustainable development making it
necessary to have secure, adequate, and competitively priced supply
while maintaining the environmental integrity. Electricity supply and
consumption directly support economic activities, with energy being
an input in almost all major economic activities in all countries.
Although diesel power plants play a significant role in stabilization of
the grid and supply of peak power and emergency power, they are
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the major cause high electricity cost, because the consumer has to
fully meet the fuel cost in addition to the actual energy cost. Diesel
power generation costs about $0.35 per kWh, while the cost of
geothermal ranges from $0.08 to $0.09 per kWh, according to the
government of Kenya . This high unit cost can be attributed to high
maintenance, operation, fuel oil and lubrication costs typical of
diesel plants. The price of power from diesel power plants consists of
the fuel element and the electricity or energy part unlike other
power plants like geothermal and hydro where the price consists of
just the energy or electricity portion.
This study targeted Kipevu I power station because it has the worst
performance among diesel power plants in terms utilization and
capacity factors .
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Diesel Power Plants in Kenya
The electric power sector was earmarked as an important sector by
the national development plan of 1994- 1996 but it heavily relied on
hydroelectric power for about 77% electricity supply. With prolonged
drought and continued growth of electricity demand, Kipevu 1 diesel
power plant was installed
Data Collection and Analysis
Data collection was coordinated and purposefully done by two
research assistants with guidance from the first author who worked
in the power station between 2016 and 2012 as both operations and
maintenance engineer. Interviews, document analysis, and
questionnaire were used to collect both qualitative and quantitative
data. Documents accessed include daily operation reports, monthly
and annual reports, as well as machine operation and maintenance
manuals with authority of the company (KenGen). Data collected was
analyzed and presented using both quantitative and qualitative
techniques. 5.2
Construction of Kipevu 1 Diesel Engine Power Plant
Kipevu 1 was commissioned in 1999 and is government owned
though KenGen. The power from the plant is used to stabilize the
voltage of power in the coastal city. [16]. Kipevu 1 has six MAN B&W
9L58/64 engines each with a capacity of 12.25MW bringing the total
capacity installed at the station to 73.5MW. The effective capacity of
the plant is 52.3MW
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Electricity Generation Data
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was not operational. Combustion quality influences engine thermal
efficiency and output and so should be monitored
Corrective maintenance
Corrective maintenance is also called repair or breakdown
maintenance and as the name suggests, it is maintenance done ones
the equipment has failed and so cannot continue running or
operating. The main challenge facing Kipevu 1 is long procurement
procedures for spares and technical services from manufacturer and
third parties for quick and quality repairs. Contract management and
exemptions from the public procurement act which slows down the
process may help.
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Plant Availability
Plant availability is a function of plant operation and maintenance.
Table 8 below shows a summary of plant availability between 19999
and 2016 as extracted from generation reports. Plant availability is a
function of plant quality of maintenance and operation of plant and
equipment hence the need for availability of quality spares, and
qualified, well trained and competent operation and maintenance
personnel in an enabling environment.
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CONCLUSION
Kipevu 1 power plant continues to face relatively poor performance
compared to privately owned power plants. A combination of
condition based, preventive and quick response to breakdown
maintenance will improve the power plant performance in terms of
capacity factor and availability. Adequate instrumentation of plant
and equipment will enhanced condition based maintenance.
However the delays in procurement of technical support services and
spare parts have contributed to poor performance of Kipevu 1 power
plant compared to privately owned and operated plants. Fuel costs
are also high and are passed down to the consumers making cost of
diesel power higher than geothermal and hydroelectric sources. Long
procurement processes in acquisition of spare parts and specialized
service cause long downtime and reduce plant availability. With
penalties for poor performance by utility company, the investor’s
income is negatively impacted compromising the power plants
sustainability and continued operation. The poor performance makes
the plant unsuitable for base load power supply to the grid. The
privately managed diesel power plants have higher availability and
capacity factor implying better operation and maintenance practices
than the publicly owned Kipevu I. Ultimately contract management
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and overhaul of procurement and maintenance practices will
effectively improve the performance of the power plant and reduce
cost of generation and hence price of electricity.
RECOMMENDATIONS
Efficient and economical operation and maintenance of diesel engine
power plants calls for technical, policy and legislative measures.
Diesel power plant operators should overhaul their technical and
operational systems to ensure quality and timely services to supply
quality, affordable and reliable power. Technically it is necessary to
build the technical capacity in terms of skills and tools to ensure
quality and timely maintenance. Delay in procurement of technical
services can be reduced by contract management, subcontracting
and exemption from the requirements of the public procurement act
for critical spares and services. Fuel cost can be reduced by
development of combined cycle plants while shift to gas from diesel
or HFO is another fuel cost saving measure. These will also reduce
environmental impact of diesel power plants. For off grid operations
which often rely on diesel power plants for remote towns with no
grid, it is recommended that hybrid systems are used. These systems
combine diesel generators with renewable sources like wind, solar or
both for 24x7 stable electricity supply.
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SUMMARY
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