Me419 Ehs Ppe DPP

ME419: Power Plant Engineering
DPP
Energy Source: Reciprocating
Engine Electricity
Fuel Power Plant
light / Diesel Fuel oil
Diesel (LFO/DFO)
 DIESEL Power Plant
Heavy Fuel Oil (HFO)
Natural Gas  HFO Power Plant
Dual Fuels: NG+ DFO
 GAS ENGINE Power Plant
 Dual Fuel Power Plant
Dec 2022, Dr. Md. Ehsan 1

Reciprocating Engine Power Plants
Power Rating Engine Type
1 -10 kW
Petrol Engines
Small Scale
10 kW – 500 kW
Diesel Engines
Medium Scale
500 kW -10 MW Diesel Engines

Large Scale Gas Engines

Reciprocating SI Engines : Otto Cycle
1 – 2 : Isentropic Compression
OTTO CYCLE
Compression ratio : 9-11 2 – 3 : Constant Volume Heat Addition
SIT : 257°C, SI, Low Fuel Pr 3 – 4 : Isentropic Expansion
4 – 1 : Constant Volume Heat Rejection
3
Dec 2022, Dr. Md. Ehsan
Reciprocating SI Engines : Otto Cycle
Spark Ignition
Spark Plug
Ignition Transformer/Coil
Voltage : 15,000 – 30,000 V
4
Reciprocating CI Engines : Diesel Cycle
Gas Power Cycle : Working fluid remains a gas throughout the cycle.
1 – 2 : Isentropic Compression
DIESEL CYCLE
2 – 3 : Constant Pressure Heat Addition
Compression ratio : 16-24
SIT : 361°C, CI, High Fuel Pr 3 – 4 : Isentropic Expansion
4 – 1 : Constant Volume Heat Rejection 5
Reciprocating CI Engines : Diesel Cycle
DIESEL CYCLE
Fuel Injectors
Compression ratio : 16-24
High Fuel Pressure : >200 bar
SIT : 361°C, CI
6
Application of ICE in PP
1. Peak load plant Diesel plants can be used in combination with
thermal or hydro-plants as peak load units. They can be easily
started or stopped at a short notice to meet the peak demand.
2. Mobile plant Diesel plants mounted on trailers can be used for
temporary or emergency purposes such as for supplying power to
large civil engineering works.
3. Standby unit If the main unit fails or cannot cope up with the
demand, a diesel plant can supply the necessary power. For
example, if water available in a hydro-plant is not adequately
available due to less rainfall, the diesel station can operate in
parallel to generate the short fall in power.
4. Emergency plant During power interruption in a vital unit like a
key industrial plant or a hospital, a diesel electric plant can be
used to generate the needed power.

Application of ICE in PP
5. Nursery station In the absence of main grid, a diesel plant can be
installed to supply power in a small town. In course of time, when
electricity from the main grid becomes available in the town, the
diesel unit can be shifted to some other area which needs power
on a small scale. Such a diesel plant is called a "nursery station".
6. Starting stations Diesel units can be used to run the auxiliaries
(like FD and ID fans, Boiler Feed Pump, etc.) for starting a large
steam power plant.
7. Central stations Diesel electric plants can be used as central
station where the capacity required is small
8. IPP Applications in some countries DPPs are used as a part of
the main electric generation network. In these a large number of
machines work in parallel to produce the total power.

Advantages of ICE in PP
1. It is easy to design and install these power plant.
2. They are easily available in standard capacities.
3. They can respond to load changes without much difficulty.
4. They occupy less space.
5. They can be started and stopped quickly.
6. They require less cooling water.
7. Capital cost is less.
8. Less operating and supervising staff required.
9. High efficiency of energy conversion from fuel to electricity.
11. Efficiency at part loads is also higher.
12. Less of civil engineering work is required.
13. They can be located near the load centre.
14. There is no ash handling problem.
15. Easier lubrication system.

Disadvantages of ICE in PP
Disadvantages
1. High operating cost.
2. High maintenance and lubrication cost.
3. Capacity is restricted. Cannot be of very big size.
4. Noise problem.
5. Cannot supply overload
Largest in BD
26 MW
MAN 20V45/60
Chandpur

DPP: Prominent Manufacturer
CATTERPILLER HYUNDAI
CUMMINS MITSUBISHI
MAN VOLVO
WARTSIA ROLLS-ROYCE
WAUKESHA WESTINGHOUSE
DUETZ ONAN
KOHLER
DETROIT DIESEL
GM
GENERIC
CULTER HAMMER
DPP: Manufacturer
12
DPP: Smaller Systems
13
DPP: System Layout
SUPERCHARGED DIESEL PLANT

14
DPP: LFO-HFO Systems
15
16
DPP: Sub-Systems
 Starting System
 Air Intake System
 Fuel Supply System
 Fuel Pre-processing System
 Fuel Injection System
 EGB: Exhaust Gas Boiler System
 Water Cooling System
 Lubricating System
 Power Generation and Take-off System
 Operation Control System
 Water Treatment System
 Fire Fighting System
18
150 MW = 9 x 16.7 MW, MAN (Germany) Model: 18V51/60DF

ENGINE
18 Cylinder, V
B x S : 510 x 600 mm
500 rpm
18 MWm per Cylinder
ALTERNATOR
12-Pole, 50 Hz,11 kV
16.6 MWe per
Alternator

DPP: Starting Systems
V16 Firing Order :

1-12-8-11-7-14-5-16-4-15-3-10-6-9-2-13

ELECTRIC STARTING SYSTEM
HYDRAULIC STARTING SYSTEM
22
COMPRESSED AIR
STARTING AIR: 25-30 Bar
(Rotates the engines at
about 150-250 rpm)
AUXILIARY AIR: 6-8 bar

(Pneumatic Control)

AIR VALVE

DPP: Air Intake System
AIR FILTRATION
Air Filter : Paper, Metallic
Mesh, Bag filters
25
DPP: Super and Turbo Charging
Mechanical Supercharger
Turbocharger 26
DPP: Turbo Charged After Cooled
TC AFTER COOLER
Compressed intake air is water
cooled before entering the
manifolds. Improved ηV .
27
DPP: Fuel System
Day Tank
Main Storage Tanks
28
DFO/ LFO (Diesel)
29
HFO (Furnace Oil)
30
Fuel Supply System for HFO
 Clean the Fuel of - Water, Sludge

 Warm up the Oil for maintaining proper viscosity
31
Pre-Processing System for HFO
Chemical Dosing:
Rotary Centrifugal
HFO Purifier:
Separates - Water,
Sludge 32
Pre-Processing System for HFO
EGB Steam Heaters:

Preheats the HFO to reduce viscosity
before being transferred to the engine.
33
DPP: HFO Processing System
OILYWATER Tank SLUDGE Tank

34
DPP: Lubricating System
Lub Oil Tanks

35
DPP: Lubricating System
Lubricating Oil Cooler
36
DPP: Exhaust System
Typical 50 m Chimney Cluster
37
EGB: Exhaust Gas Boiler
EGB: Water Tube, using Exhaust Heat

Aux. Boiler: Fire Tube, for starting
STEAM is mainly used in heating the

HFO to maintain the required viscosity
38
EGB: Water Tube, 10 Bar, SH 187°C, 2.5 T/h

Steam Header
39
EGB: Fire Tube, 11 Bar, SH 189°C, 3 T/h

Exhaust intake from 3 generators
40
DDP: Water Cooling System
Low Temp Loop: 40-60°C

(After Cooler, Lub Oil)
High Temp Loop: 75-95°C
(Water Jacket)
41
2 MW
&
1 MW
CAT GAS
ENGINE
RADIATORS
42
DPP : Alternators
12 Pole
Air cooled
Directly
Coupled
Alternator
(500 rpm)
43
DPP : Power Evacuation
11 kVA to 132 kVA

STEP-UP
TRANSFORMERS
44
Fuel Supply System for Gas Engines
45
RMS-Regulating and Metering System
1. Welding Neck Flange
2. Insulating joint
3. Isolating Valve
4. Pressure Gauge
5. Ball Valve
6. Filter
7. Slam Shut valve
8. Pressure regulator
9. Pressure Gauge
10. Safety Relief valve
11. Water Check valve
12. Ball Valve
13. Gas metering
14. Volume Corrector
15. Temperature Gauge
16. Insulating Joint
17. Neck Flange
Industrial RMS unit 46

RMS-Regulating and Metering System
Industrial RMS unit

47
Fire Safety
WATER
HYDRANT
FIRE FIGHTING
FOAM TANKS
48
DPP Problems
Problem # 1
Following are the observations made for a 20 minute trial of a two-stroke
diesel engine.
Net brake load = 680 N, mep = 3.0 bar, N = 360 rpm, Fuel consumption
= 1.56 kg, Cooling water = 160 kg, Water inlet temperature = 32°C,
Water outlet temperature = 57°C, Air used/kg fuel = 30 kg, Room
temperature = 27°C, Exhaust gas temperature = 310°C, Cylinder
dimensions = 210 mm bore x 290 mm stroke, Brake diameter = 1m,
Calorific value of fuel = 44 MJ/kg, Steam formed per kg fuel in the
exhaust = 1.3 kg, specific heat of steam in exhaust = 2.093 kJ/kgK,
Specific heat of dry exhaust gases = 1.01 kJ/kgK.
Calculate the indicated power and the brake power and make an energy
balance of the engine.
49
DPP Problems
Problem #2
During a test on a diesel engine used for driving a dc generator, the
following observations were made.
The output of the generator was 215 A at 210 V, the efficiency of the
generator being 85%. The quantity of fuel supplied to the engine was
11.8 kg/h, the calorific value of fuel being 43 MJ/kg. The air-fuel ratio
was 18:1.
The exhaust gases were passed through an exhaust gas calorimeter
for which the observations were as follows:
Water circulated through the calorimeter = 560 litres/h, Temperature
rise of water = 38°C, Temperature of exhaust gases at exit from
calorimeter = 97°C, Specific heat of exhaust gases = 1.04 kJ/kgK,
Ambient temperature = 30°C.
If the heat lost to the jacket cooling water was 32% of the total energy
released by combustion, draw up energy balance sheet of the engine.
50
DPP Problems
Problem # 3
A four-stroke CI engine of 3.5 litre capacity develops indicated power

on average of 13.1 kW/m3 of free air induced per minute, while running
at 3600 rpm and having a volumetric efficiency of 82%, referred to free
air conditions of 1.013 bar and 25°C. A blower driven mechanically from
the engine is proposed to be installed for supercharging. It works
through a pressure ratio of 1.75 and has an isentropic efficiency of
70%. Assume that at the end of the intake stroke the cylinders contain
a volume of charge equal to the swept volume, at the pressure and
temperature of the delivered air from the blower. Taking all mechanical
efficiencies to be 80%, estimate the net increase in brake power of the
engine due to supercharging.
51

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ME419: Power Plant Engineering

 Dual Fuel Power Plant

Dec 2022, Dr. Md. Ehsan 1

Power Rating Engine Type

500 kW -10 MW Diesel Engines

Dec 2022, Dr. Md. Ehsan 2

Dec 2022, Dr. Md. Ehsan 7

Dec 2022, Dr. Md. Ehsan 8

Dec 2022, Dr. Md. Ehsan 9

Dec 2022, Dr. Md. Ehsan 10

SUPERCHARGED DIESEL PLANT

150 MW = 9 x 16.7 MW, MAN (Germany) Model: 18V51/60DF

Dec 2022, Dr. Md. Ehsan 19

Dec 2022, Dr. Md. Ehsan 20

V16 Firing Order :

Dec 2022, Dr. Md. Ehsan 21

HYDRAULIC STARTING SYSTEM

AUXILIARY AIR: 6-8 bar

Dec 2022, Dr. Md. Ehsan 23

Dec 2022, Dr. Md. Ehsan 24

 Clean the Fuel of - Water, Sludge

EGB Steam Heaters:

OILYWATER Tank SLUDGE Tank

Lub Oil Tanks

Lubricating Oil Cooler

EGB: Water Tube, using Exhaust Heat

STEAM is mainly used in heating the

EGB: Water Tube, 10 Bar, SH 187°C, 2.5 T/h

EGB: Fire Tube, 11 Bar, SH 189°C, 3 T/h

Low Temp Loop: 40-60°C

11 kVA to 132 kVA

Industrial RMS unit 46

Industrial RMS unit

A four-stroke CI engine of 3.5 litre capacity develops indicated power

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