530312901B001 Technical Specification.docx

MAN Diesel & Turbo
24,8 MW Gas Power Plant
Iran
Technical Specification
2 MAN Gensets 20V35/44GTS plus basic equipment supply
Our Reference 5303129-01-B001
5303129_24,8MW Gas Power Plant_2x20V3544GTS_Technical Specification_Rev0.docx
Page i
MAN Diesel & Turbo
Table of Contents
1
Design data and performance guarantees
1
1.1
1.2
Design data
Performance data
1
4
2
Gas engine 35/44GTS
7
2.1
2.2
Engine System
Detailed Technical Specification of one engine 35/44GTS
3
Generating set
12
3.1
3.2
Connecting elements
Genset
13
13
4
Mechanical scope
4.1
4.2
4.3
Auxiliary systems, engine related
Auxiliary systems, plant related
Exhaust gas system
5
Electrical scope
5.1
5.2
Control and monitoring system
Electric plant system
6
Miscellaneous
6.1
Documentation
7
Tools, spare and wear parts
7.1
Tools and spares
8
Services
8.1
8.2
8.3
8.4
8.5
Quality Management, Quality Assurance
Project engineering
Logistics
Site activities
Project services
33
34
36
36
39
9
Requirements and limitations
41
9.1
9.2
Quality requirements for operating media
Limits of supply
41
44
10
Standards and Guidelines
10.1
10.2
Applicable standards
General guidelines
11
List of sub suppliers
47
12
Drawings
48
12.1
Drawing of the generating set 11.74500-1847
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8
10
16
16
19
22
24
24
26
30
30
31
31
33
45
45
45
48
Page ii
24,8MW Gas Power Plant
Section 1 - Design data and performance guarantees
1
1.1
Design data and performance guarantees
Our quotation is based on the following design data as well as the
− Drawing of the generating set 11.74500-1847
Design data
1.1.1
Site conditions
Site conditions
All offered equipment is designed to operate within the following ambient conditions:
− Altitude above sea level
1100 m
− Wet bulb temperature
20 °C
− Minimum ambient air temperature
-20 °C
− Maximum ambient air temperature
40 °C
Operation outside of these limits is without guarantee.
1.1.2
Generating sets
Generating sets
In response to your request, this quotation is for 2 generating sets based on
the MAN 20V35/44GTS engine.
− Number of generating sets
2
− Engine type
20V35/44GTS
-1
− Engine speed
750 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
base load
− Frequency
50 Hz
− Power factor Cos φ (lagging)
0,8
− Medium voltage
11 kV
− Low voltage
400 V
Electrical
system
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24,8MW Gas Power Plant
Section 1 - Design data and performance guarantees
1.1.3
Foundation
Lube oil
Cooling method
Fuel system
Intake air
Exhaust gas
Power house
ventilation
Other design data
1
2
− Soil bearing capacity
> 200 kN/m
Earthquake design according to Peak Ground Acceleration
2
− PGA
0,4 g
Engine lube oil has to be in accordance with the requirements as stated in
section 9.1.1
Requirements for viscosity:
− Viscosity class (40°)
SAE 40
The cooling system is designed for cooling water in accordance with the requirements as stated in section 9.1.2.
Features of the cooling water system:
− Type of cooling system
radiator
The fuel system is designed based on the fuel gas in accordance with the requirements as stated in section 9.1.4.
Ambient air
dusty and sandy air,
aspirated from outside power house
Intake air has to be in accordance with the requirements as stated in section 9.1.5.
Exhaust gas concept
Vertical silencer with tail pipe
Height of stack
16 m
The powerhouse ventilation air is blown directly onto the alternator.
The maximum temperature inside power house, measured at floor level, next
to engine / alternator is 50 °C (tambient + 10 K). At gallery level a temperature of
55 °C (tambient + 15 K) is permissible.
The alternator design temperature is 43 °C.
1
2
The complete offer is based on the abovementioned minimum soil bearing capacity
with a low settlement.
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
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24,8MW Gas Power Plant
Section 1 - Design data and performance guarantees
Permissible
frequency limits
in grid parallel
operation
Load
application in
island mode
Table 1: Diagram of permissible frequency and load limits in grid parallel operation
Table 1 show 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 fluctuations for maximum
120 seconds. In any case, the maximum permissible mains grid frequency
deviation is ±5%.
In grid parallel operation, the frequency of the grid varies according to the current consumer load and the input from power suppliers. The plant responds as
described above.
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 15% 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.
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24,8MW Gas Power Plant
Section 1 - Design data and performance guarantees
It is an intrinsic property of the power train of a generating set that it acts as a
torsional vibration system. This complex system consists of the engine, coupling and generator (within scope of MAN Diesel & Turbo), the plant’s electric
network, consisting of further power producers and consumers, transformers,
bus bars or circuit breakers and the power grid (not within scope of MAN Diesel & Turbo). The reciprocating engine, as well as the power grid or the other
consumers and producers excite the system. As a consequence, the active
power at the generator terminals is not completely constant with respect to
time and some additional power oscillations so-called power fluctuations occur.
These power fluctuations do not affect the operational safety of the generating
set. In addition, this behavior is in accordance with ISO 8528-5 and does as
per MDT experience not affect net stability in an unacceptable range. Gas
operated engines tend to show higher load fluctuations than engines operated
on diesel fuels. This belongs to the typical cyclical fluctuations of the Otto
combustion process that uses a premixed combustion. In general, it is expected that power fluctuations are higher in net-parallel operation than in island-mode.
Please note that MAN Diesel & Turbo quotations do not consider any specific
limitations regarding power fluctuations.
Power
fluctuations
1.2
Site Reference
conditions
Measuring
tolerances
Performance data
The guarantee data is shown in underlined bold letters. Other values are for
information only and without guarantee.
The 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)
30 °C
− Wet bulb temperature
20 °C
− Air Inlet pressure (before air inlet filter)
888 mbar
− Charge air temperature before cylinder
50 °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 with 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 3046-1:2002).
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Section 1 - Design data and performance guarantees
Continuous power of the generating set
The continuous power of one generating set 20V35/44GTS at above defined
reference conditions is:
Continuous power of the generating set
12065 kWel
The abovementioned power is the electrical output of the generating set as
measured at the generator terminals. The generator efficiency is calculated
with 97,3%
Applicable standard is ISO 3046. The continuous power of the generating set
at other site altitudes as defined above is shown in the following diagram.
14000 kW
Genset Power [kWel]
1.2.1
12000 kW
12065 kW
12065 kW
10000 kW
8000 kW
6000 kW
4000 kW
2000 kW
0 kW
0
400
800
1200
1600
Altidude [m]
Table 2: Power in relation to site altitude
If the gas' methane number is less than 70, the power of the generating set
needs to be reduced. Injection and ignition need to be adjusted.
Natural gas with a methane number less than 60 cannot be used.
Corresponding to ISO 3046-1:2002, clause 11.3 and ISO 8528-1:2005, clause
13.3, the engine power will be blocked at 110 % load of the MCR, whereas the
10 % overload will be used for governing purposes only; it shall not be used for
the supply of electrical consumers.
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24,8MW Gas Power Plant
Section 1 - Design data and performance guarantees
1.2.2
Specific fuel gas consumption (SFC)
The specific fuel gas consumption at continuous power as per section 1.2.1
and at above defined reference conditions will not exceed the following value:
Specific fuel gas consumption
7732 kJ/kWhel
+ 0 % tolerance.
Genset efficiency
46,6%
Remark: The specific fuel gas consumption is valid for fuel gases with a Net
3
Calorific Value (NCV) of min. 32,400 kJ/m³ (STP) and a methane number =
80. Worse natural gases require further calculation/engine design.
The stated guaranteed value is based on ISO 3046-1:2002. Corrections due to
site conditions differing from the site reference conditions stated above must be
executed according to the MAN standard procedure. The value stated above is
the average of all generating sets.
1.2.3
Lubricating oil consumption
The lube oil consumption of one generating set at reference conditions as
defined above will not exceed the following value:
Lube oil consumption
4,3 kg/h
+ 20 % tolerance.
The value stated above is without any losses due to cleaning of filter or lube oil
charge replacement.
The stated guaranteed value is based on ISO 3046-1:2002. Corrections due to
site conditions differing from the site reference conditions stated above must
be executed according to the MAN standard procedure. The value stated
above is the average of all generating sets.
1.2.4
Exhaust gas emissions
4
The exhaust gas emissions at continuous power as per section 1.2.1 and at
guarantee conditions as defined above will not exceed the following values:
Nitrogen oxide (NOx)
200 mg/Nm³
at 15% O2 in dry exhaust gas. Measuring after the engine.
The nitrogen oxide (NOx) value is calculated as NO2 contingent and on the fuel
gas as defined in section 9.1.
Applicable standards for exhaust gas emissions: Pollution Prevention and
Abatement Handbook, Part III, The World Bank Group, 2007/2008.
O2 and NOx measurements as per ISO-8178.
3
4
If the methane number is below the minimum, the engine output has to be reduced
and the ignition-/injection have to be adjusted.
Reference conditions to a normal cubic meter (Nm³):
pressure = 1,013 mbar, temperature = 0°C.
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24,8MW Gas Power Plant
Section 2 - Gas engine 35/44GTS
2
General
description
Gas engine 35/44GTS
The MAN engine 20V35/44GTS is a
four-stroke, medium-speed gas engine,
2 stage turbocharged and charge aircooled. The engine is spark-ignited,
prepared for operation on natural gas.
Compared to other medium-speed engines, within the same power range, the
20V35/44GTS produces high power
from a compact, efficient design.
5
Technical data
The technical data of the engine at ISO conditions is summarized in the following table:
− Cylinder bore
350 mm
− Piston stroke
440 mm
-1
− Engine speed
750 min
− Piston speed
11 m/s
− Mean effective pressure
23,4 bar
− Power per cylinder
620 kW/cyl
− Power of the engine (at crankshaft)
12400 kW m
Continuous
development
The engine family is developed specially for stationary power generation. This
new and highly efficient spark-ignited gas engine is ideal not only for decentralized applications, but also as prime mover in large base load power applications up to 200 MW. The engine type is based on the proven gas engine
35/44G and is subject to continuous development to ensure reliability under the
most severe service conditions.
Outline
dimensions
6
Dimensions and weight of the engine 20V35/44GTS:
− Height (H)
− Length (L)
− Width (W)
− Weight (dry)
5
6
5200 mm
11549 mm
4925 mm
146000 kg
Standard Reference Conditions according to ISO 15550 Section 5:
Air temp = 25°C, CW temp = 25°C, Air pressure = 1.000 mbar, humidity = 30%,
SFOC including attached pumps
The dimensions and weight stated correspond to the engine only. All given masses
are valid for a dry engine without lube oil and cooling water. Dimensions and weights
are for guidance only and subject to change without notice.
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24,8MW Gas Power Plant
Section 2 - Gas engine 35/44GTS
Item
010
MJA10 AV010
Q’ty Description
2.1
Engine System
2.1.1
Engine System
2
2.1.2
010.220.010
MJV21 AP050
2
2.1.3
Engines 20V35/44GTS, mounted on steel foundation frame, suitable for operation on natural gas, as per following detailed Technical Specification
Lubrication system
Engine attached lube oil pump(s)
Cooling water system
010.230.010
2
Engine attached HT cooling water pump
Capacity approx. 140 m³/h
010.230.020
2
Engine attached LT cooling water pump
nominal capacity 225 m³/h. The cooling water flow through the charge air cooler will be adapted to 225 m³/h by installation of orifices.
MJG31 AP030
MJG32 AP030
2.1.4
010.285.070
2
Engine control system SaCoS One
SaCoSone Interface cabinet
The Interface Cabinet is the interface between the engine electronics and the
plant control system. It is the central connecting point for electric power supply
to the engine from the plant power distribution. Besides, it connects the engine
control system with the power management and other periphery parts.
Properties:
Each interface cabinet is located in the engine hall next to the engine.
This floor-standing cabinet (H 2,200 mm x W 1,200 mm x D 400 mm) has lockable front doors with rubber gasket. Cable insert from bottom through plinth.
Panel protection degree is IP55, color light grey (RAL7035) with plinth in umbra
grey (RAL7022). It is equipped with a gateway module for plant communication
via interfaces to the plant automation system.
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24,8MW Gas Power Plant
Section 2 - Gas engine 35/44GTS
Item
Q’ty Description
010.285.080
2
SaCoSone Auxiliary Cabinet
The Auxiliary Cabinet contains the driver unit for the speed governor as well as
the starters for the engine attached motors.
Properties:
Each Auxiliary Cabinet is located in the engine hall next to the engine.
This floor-standing cabinet (H 2,200 mm x W 1,200 mm x D 400 mm) has lockable front doors with rubber gasket. Cable insert from bottom through plinth.
Panel protection degree is IP55, color light grey (RAL7035) with plinth in umbra
grey (RAL7022). Starters for engine attached cylinder lubrication pump as well
as temperature control valves for cooling water.
010.285.120
2
Control cabinet for gas control line
Wall mounted cabinet, consisting of I/O modules for monitoring of the gas control line
010.285.130
2
Turbocharger control unit
2.1.5
010.330.020
1
Factory Acceptance Test (FAT)
Factory Acceptance Test of one engine
The test will be done with the MAN Diesel & Turbo test bed 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 natural gas 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
ascertained on the test bed. The measuring parameters, including relevant
accuracies, are based on ISO 3046.
Extension or changes of our test program would result in additional cost and
have to be clarified upon request.
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24,8MW Gas Power Plant
Section 2 - Gas engine 35/44GTS
2.2
Detailed Technical Specification of one engine 35/44GTS
Design features
One-part crankcase with safety valves on crankcase covers
Crankshaft made of forged steel with torsion 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 (split with flange) drop-forged from steel
Piston with forged steel crown and steel skirt
Cast-iron cylinder liners with fire land ring
Nodular cast-iron cylinder head with armor-plated inlet and exhaust valves,
valve seat rings for the inlet and exhaust valves. Valve rotators on the inlet and
exhaust valves.
Pipes on the engine with counter flanges or connecting screws
Natural gas and
ignition system
The 35/44GTS is an Otto gas engine with spark plugs.
Electronically controlled gas valves, individually for each cylinder
Gas supply line with indicator filter, shut-off by means of solenoid valve
The ignition system provides a scavenged pre-chamber, optimized for low NOx
emissions and stable ignition. The ignition system using spark plugs ensures
reliable ignition.
Turbo charging
and charge-air
cooling
Two-stage turbo charging with intermediate charge air cooling, installed on a
free-standing module, decoupled from the engine, consisting of:
2 low pressure turbocharger, one for each cylinder bank. Dry cleaning device
for the exhaust gas turbine and wet cleaning device for the compressor.
2 charge air cooler after low pressure stage in fresh water and two-stage design; with counter flanges
2 high pressure turbocharger, one for each cylinder bank. Wet cleaning device
for the exhaust gas turbine.
2 charge air cooler after high pressure stage in fresh water and two-stage design; with counter flanges
Waste gate to increase the exhaust gas temperature after engine
Air pipe sound insulated between compressor and charge air cooler (including
air intake casing)
Exhaust gas piping on the engine, un-cooled, thermally insulated and lagged
Operation and
control
Engine safety and control system SaCoSone, comprising of:
SaCoSone Injection unit
resiliently mounted on engine, consisting of injection module(s) for electronic
speed governing and gas injection valve control
SaCoSone Control unit
resiliently mounted on engine, consisting of highly integrated control modules,
one for safety system and one for alarm handling and control, including the
following functions:
− Splash oil 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 over speed protection
− Engine control
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24,8MW Gas Power Plant
Section 2 - Gas engine 35/44GTS
SaCoSone Atex unit
resiliently mounted on engine, consisting of explosion protected I/O modules
for main bearing monitoring
SaCoSone Knock control unit
resiliently mounted on engine, consisting of knock detection device
Local operating panel
resiliently mounted on engine, with TFT touch screen for:
− Indication of engine operating data
− Indication of status and alarm messages
− Engine start/stop
− Control station change-over
− Increase/decrease of speed set point
− Emergency stop
Oil mist detector Schaller VN115
Temperature
measuring
Thermocouples for measuring the exhaust gas temperature after each cylinder,
before and after turbocharger
Lubricating and
cooling
Forced-feed lubrication for all bearing points of running gear, camshaft, timing
gear and turbocharger
Cylinders, cylinder heads and charge-air coolers are water-cooled, pistons are
oil-cooled
Starting system
The engine uses a compressed air starter that transmits the torque directly to
the flywheel. The starter module also includes a flexible turning gear.
Engine painting
The exterior surface of the engine is painted in WINDOW GRAY (RAL7040).
Painting consists of one finishing coat, approx. 20 µm.
Acceptance
Works acceptance / factory approval.
Calculation
Torsion vibration calculation
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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.
Outline
dimensions
7
Dimensions and weight of the generating set:
− Height (H)
− Length (C)
− Width (W)
− Weight (dry)
7
5200 mm
15686 mm
4925 mm
188000 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 for guidance only and are subject to change without notice. The length of the genset unit depends
on the alternator make.
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Section 3 - Generating set
Item
Q’ty Description
3.1
3.1.1
Connecting elements
Coupling arrangement
020.010.010
2
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
2
Flywheel cover
MJK10 AU010
MJP10 AU011
3.1.2
Pipe adapters
020.030.025
2
Flexible pipe connections for the engine
020.030.080
4
Rubber expansion joint for intake air duct
to be installed upstream of turbocharger, delivered with counter flange.
3.2
3.2.1
025.020.010 -1
MKA10 AG010
2
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
ensure 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 withstand 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.
15081 kVA
− Voltage
11 kV
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Section 3 - Generating set
Item
Q’ty Description
− Current approx.
792 A
− Frequency
50 Hz
− Power factor
0,8
− Temperature rise stator/rotor
F/F
− Insulation class
F
− Mounting design
IM1001 or IM7201
− Protection class alternator
IP23
− Protection class terminal box
IP54
− Cooling method
IC0A1 (Air cooled)
− Operation
S1, continuous
− Operation mode
− 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
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 color
− Foundation bolts
Final series test report according to manufacturer's standard is included.
025.020.050
2
Automatic voltage regulator (AVR)
Digital excitation control system type BASLER DECS 250 installed on a mounting plate integrated in the Genset Interface Panel (GCP).
Features:
− Voltage Regulation accuracy <0,25%
− Proportional (P), integral (I) and derivative (D) stability control
− Limiter functions to ensure, that the alternator does not exceed its capabilities, e.g. Over/Under Excitation Limiter, Stator Current Limiter, V/Hz Limiter
− Paralleling compensation of two or more alternators using reactive droop
− Automatic Voltage Regulation Mode (AVR Mode), Power Factor Mode,
Field Current Regulation (Manual Mode)
− Several protection functions (e.g. Loss of sensing voltage, Loss of excitation)
− Rotating Diode Monitoring
− Serial bus coupling interface for read out of different measuring values
− Synchro check relay functionality
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Section 3 - Generating set
Item
Q’ty Description
3.2.2
Foundation system
025.030.030
2
Grouting material for seating of alternator
025.030.050 -2
2
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.
MJA10 BF021
3.2.3
025.035.060
2
Genset add-ons
Lube oil tank level monitoring
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Section 4 - Mechanical scope
4
Item
Mechanical scope
Q’ty Description
4.1
4.1.1
Auxiliary systems, engine related
Lube oil service system
030.020.010 -1
2
Lube oil module
consisting of:
− Lube oil heat exchanger
− 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.
030.020.150
2
Lube oil replenishing and flow rate measuring device
Consisting of:
− Oval gear meter including pulse trigger
− Solenoid valve
030.020.270
2
Lube oil fine filter
Consisting of:
− Fine filter with cartridge
− Feed pump with motor (2-3 times circulation of lube oil volume in 24 hours).
− Pressure switch to indicate cartridge change.
Fine filters are simple to operate and do not need any process water. The filters
can be changed quickly and easily without engine shutdown.
030.020.280 -1
2
Oil mist fan
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. The oil mist eliminator reduces the oil emissions from the
vents of the engine crankcase chamber and the turbocharger.
030.020.290
2
Lube oil preheating pump
Pump for lube oil circulation in the pre-heating circuit.
MJV21 AC010
MJV23 AA010
MJV22 AT040
MJV28 AT010
MJV21 AP040
4.1.2
030.030.035
MJG31 AP020
2
HT cooling water service system
Cooling-down pump, free-standing
Capacity 30 m³/h, with e-motor.
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
030.030.035 -1
2
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
mixing point.
030.030.035 -2
2
Resistance thermometer for HT cooling water, loose supply
030.030.060
2
Cooling water expansion tank
The tank is designed with two separate compartments for HT and LT circuit,
capacity 500 l/250 l, with mechanical level indicator and minimum alarm contact
MJG31 AP020
MJG31 AP020
MJG31 BB011
4.1.3
Low temperature cooling water system
030.040.050 -1
2
Charge air temperature control valve (CHATCO)
030.040.050 -2
2
Resistance thermometer for charge air temperature
030.040.050 -3
2
LT cooling water temperature control valve
with electric actuator and resistance thermometer Pt100, to be installed in LT
cooling water pipe downstream the mixing point
MJG32 AA025
MJG32 AA025
MJG32 AA025
4.1.4
030.050.010 -1
MJG32 AC020
2
Two circuit radiator cooling system
Two-circuit radiator cooling system
The engines are cooled with outside mounted 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 -20 °C (with
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 110 dB(A).
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
4.1.5
Fuel gas system
030.100.010
2
Gas control line
Rated for gas supply overpressure as per minimum requirements for natural
gas, consisting of:
− Shut-off valve
− Gas filter
− Pressure gauges / pressure switch
− Gas regulator system with safety shut-off
− 2 Trip action stop valves
− 2 Main venting valves
− Terminal box, explosion-proof.
The maximum allowed distance between the gas control line outlet and the
engine gas inlet is 10 m. The piping between gas control line and engine gas
inlet has to be made of stainless steel (min. X6CrNiMoTi17-12-2, being fluid
and ambient resistant).
030.100.050
2
Set of shut off valves for natural gas
Consisting of:
− main shut off valve
− shut off valve for priming the main gas pipe
− venting valve
As an additional safety and maintainability measure MDT recommends the
installation of a manual ball valve within the natural gas supply line in each
engine related branch in front of the power house. This valve is not in scope of
supply of MDT.
EKG91 BP010
EKG91 AA020
4.1.6
030.120.010 -1
MJQ61 AT010
2
4.1.7
030.130.020
2
Combustion air system
Intake air filter unit
Consisting of:
− Weather protection
− Droplet separator
− Pulse filter, self-cleaning with pressurized air
− Silencer for a noise attenuation of approx. 40 dB(A)
− Transition piece to intake air duct(s)
− Intake air pre-heating
− Filter control unit
Engine exhaust gas system
Expansion joint for exhaust gas duct
to be installed after adapter, without counter flange
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
4.2
4.2.1
Auxiliary systems, plant related
Lube oil supply system
040.010.010
1
Lube oil preheater set
To heat engine lube oil to 40°C before engine start, heating capacity 48 kW,
consisting of:
− Temperature controller with limiter
− Temperature sensor
− Safety valve
− Switch cabinet with control and power part
− Saddle support.
The preheater set is designed to preheat the lube oil of one engine.
040.010.030
2
Lube oil supply pump
1 x operation and 1 x stand-by, capacity 3 m³/h each, with e-motor. The pump
is used to supply lube oil from the storage tank to the service tank.
040.010.040
1
Lube oil transfer pump
Capacity 3 m³/h, with motor 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.
MJV21 AC020
MJV23 AP030
MJV23 AP060
4.2.2
040.030.010
MJG31 AC010
1
4.2.3
HT cooling water supply system
Pre-heater set for cooling water
After a longer engine shut down pre-heating is necessary before the start-up of
the engine. A pre-heater set delivers the necessary energy. A circulating pipe
interconnects the pre-heating set with the engine.
Cooling water pre-heating module, consisting of:
− Continuous flow water heater, electrical type (heating capacity approx. 120
kW)
− Temperature regulator
− Switch cabinet, ready for connecting and service, with control and power
part.
The preheater is designed for heating the engines consecutively.
Main water supply system
040.040.010
1
Cooling water collecting tank
Capacity 3000 l with mechanical level indicating.
040.040.020
1
Replenishing pump module
Consisting of 2 pumps (1 x operation + 1 x stand-by), capacity 3 m³/h each,
with e-motor and expansion pot, capacity 200 l.
GBK35 BB050
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
4.2.4
040.065.010 -1
UMF15 CQ010
1
4.2.5
Fuel gas system
Gas alarm unit
Consisting of:
− Monitoring panel
− Set of gas detectors
The final locations of the gas detectors in the powerhouse have to be verified
by customer (e.g. with smoke plume test). In case of gas alarm (highest stage)
all equipment within the monitored area, which can be a source of ignition,
needs to be de-energized/ black.
Starting air system
040.070.010
2
Starting air receiver
Capacity 3000 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 2 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.
040.070.030
2
Automatic draining equipment for starting air receiver
040.070.040
1
Compressor module
Consisting of 2 compressors with electric motor, 30 bar pressure, capacity 120
m³/h each at 20°C 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, flywheel and flexible coupling.
Equipment mounted on a skid for resilient mounting.
SCB71 BB010
SCA71 AT020
SCA71 AN010
4.2.6
040.073.010
QFB72 BB010
1
Control air system
Control air receiver
Capacity 1000 l, 11 bar maximum pressure, vertical receiver, hot galvanized,
with safety valve, pressure gauge and condensate discharge valve.
The control air receiver to be installed in the power house.
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
040.073.030
1
Control air compressor module
Consisting of 1 screw type compressor, 10 bar pressure, air cooled, designed
for continuous operation.
Complete module with energy saving screw type compressor block, threephase motor, belt drive with automatic belt tensioner or flexible coupling, intake
air filter, electro-magnetic water drain, final air cooler. Flexible hose line and
cyclone separator with electro-magnetic condensate trap are part of the module
or supplied as separate components.
Equipment being part the module is installed on a steel frame inside a housing
with operator control module.
040.073.050
1
Control air adsorption dryer
Dehumidification of control air down to a pressure dew point of -20°C. Dryer
consisting of:
− Two adsorbent tanks
− Valves for automatically regulated drying cycle
− Valve and pressure indicator for regeneration air adjustment
− Automatic condensate discharge
− Humidity indicator for visual check
− Inlet and outlet filter
Above mentioned equipment will be supplied installed on a steel frame for floor
installation or as unit for wall-fastening. An additional filter element will be supplied as separate component for backup purpose or special requirements.
040.073.060
1
Pressure reducing station 30/10 bar
The pressure reducing station is connecting starting air and control air. The
starting air pressure is reduced to 10 bar, to provide control air to the plant
related systems. It is used as back-up for the control air compressor.
Reducing station, complete with:
− Air filter
− Reduction valve with pressure indicator
− Safety valve
− Connectors and pipes.
040.073.070
2
Pressure reducing station bar
The pressure reducing station is used to provide control air to the plant related
systems. 1 x operation + 1 x stand-by.
The reducing station is equipped with:
− Air filter
− Reduction valve with pressure indicator
− Safety valve
− Connectors and pipes.
040.073.080
1
Compressed air filter
QFA72 AN020
QFB72 AT020
QFA71 AA010
QFB72 AA010
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
4.2.7
040.083.010 -1
UMF15 AN010
2
4.2.8
040.086.030 -1
UMF15 BS020
2
4.2.9
040.120.010
1
4.3
4.3.1
060.005.010
MJR65 BS010
2
Power house inlet ventilation system
Set of inlet ventilation units
Consisting of 2 units, equipped with:
− High efficiency ventilator
− Silencer with noise attenuation of approx. 30 dB(A)
− rain-proof housing
− Adjustable flaps with electric actuator
− Weather louvre
Units including supporting structure, maintenance platform, ladders.
Power house outlet ventilation
Power house ventilation outlet unit
The outlet units in the roof consists of weather protection and silencer with a
noise attenuation of approx. 20 dB(A)
Turning gear
Electric drive set for turning gear
Exhaust gas system
Exhaust gas silencer
Freestanding exhaust gas silencer:
Silencer for vertical installation outside of the power house (freestanding) on a
supporting steel structure,
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:
− Static design
− Corrosion protection of non-insulated external surfaces
− Fixing accessories for vertical installation on a supporting steel structure
− Delivery loose, without counter flange and insulation material
− Insulation works by Third Parties according to engineering specification
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24,8MW Gas Power Plant
Section 4 - Mechanical scope
Item
Q’ty Description
4.3.2
060.010.130
MJR65 AN020
2
4.3.3
060.020.011
MJR65 BR020
Exhaust gas duct
Ventilation system for exhaust gas duct
A ventilation system is installed for natural gas and dual fuel engine applications. The module is placed inside the powerhouse at the exhaust gas duct
close to the engines outlet. The flue gas system must be purged with fresh air.
The purging with fresh air avoids the ignition of explosive gas compositions.
During normal operation of the engine the module is protected from the hot
exhaust gas by two shut­ off valves before the fan. The valves are normally
closed. They are opened only during the ventilation. The gas tight closing is
guaranteed by sealing air, which is inserted between the valves. The ventilation
system consists of:
− Air fan with suction filter
− Two shut-off valves with limit switches
− Sealing air connection
− Pressure sensor to check the functionality of the fan
− Temperature sensor to guarantee no hot exhaust gas enters the fan
− Skid with premounted and cabled system
− Junction box
Exhaust gas stack
10 meter of exhaust gas stacks
for each MAN Diesel & Turbo engine, to be installed on top of the vertically
mounted silencer. Lengths of each tail pipe 5 m.
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24,8MW Gas Power Plant
Section 5 - Electrical scope
5
Item
Electrical scope
Q’ty Description
5.1
Control and monitoring system
5.1.1
Genset control panel (GCP_NG)
070.021 -1
2
Genset control panel (GCP_NG)
Purpose:
The new generation of the Genset Control Panel (GCP_NG) controls and supervises the GenSet (engine and alternator) and their systems in combination
with the local engine control SaCoS. It realizes the control, synchronization and
protection of the alternator circuit breaker in MV switchgear and accomodates
the AVR. The GCP is located in the control room.
Properties:
The GCP is arranged for floor mounting without plinth, totally closed and front
door with rubber gasket. Door lever is key-less. Cable insert from bottom. Connection to the alternator medium voltage switchgear, neutral earthing switchgear and SCADA system. Also connected to Common Control Panel (CCP) for
safety related signals and to Fire Fighting and BCP (Boiler Control Panel) for
safety relevant signals.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 800mm
− Height:
approx. 2000mm
− Depth:
approx. 600mm
The panels are equipped with door fans and roof mounted top filters. AC 230 V
UPS power supply input for generation of 24 V DC for control. With touch panel
for operation, supervision and monitoring. With panel light and socket outlet
(AC 230V).
− Panel protection degree
IP41
− Color
RAL 7035
Alternator protection:
− Digital multifunction protection relay
Control system (PLC):
− Siemens SIMATIC System S7-400.
Integrated devices:
− Automatic Voltage Regulator (item 025.020.050).
070.021 -2
1
Common control panel (CCP)
Purpose:
The Common Control Panel (CCP) controls and supervises the plant related
(not genset related) equipment of the power plant. Furthermore, it realizes the
protection and synchronization of the step-up transformers and the station
transformers, the medium voltage bus bar couplers and the outgoing feeders
whichever is applicable. The CCP is located in the control room.
0
0
Properties:
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24,8MW Gas Power Plant
Section 5 - Electrical scope
Item
Q’ty Description
The CCP is arranged for floor mounting without plinth and front door with rubber gasket. Door levers are key-less. Cable insert from bottom. Connection to
SCADA system.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 3200mm
− Height:
approx. 2000mm
− Depth:
approx. 600mm
Cooling is realized by door fans and roof mounted top filters
AC 230 V UPS power supply input for generation of 24 V DC for control
With touch panel PC for operating and supervision by MAN Diesel & Turbo
SCADA visualization system
With panel light and socket outlet (AC 230V)
− Panel protection degree
IP41
− Color
RAL 7035
Protection:
− 1 multifunctional protection relay for step-up transformer
− 1 multifunctional protection relay for station transformer
− 1 protection relay for MV bus bar
− Independent over current time relays for neutral earthing protection
Control system (PLC):
− Siemens SIMATIC System S7-400
5.1.2
070.090.010
1
CoCoS-System
"CoCoS-EDS" engine diagnosis system
CoCoS EDS is a personal computer-based system for the supervision of plant
operation, which allows the user far more than simply the visualization of current operating data in various forms (monitoring function).
The engine diagnosis system consists of:
Hardware
− 1
Personal computer with interface card to the alarm system
− 1
colour monitor
− 1
keyboard
− 1
printer
Software:
− Software for recording of values measured by the
− Engine-specific data and maps.
Trends
The trend function of CoCoS EDS allows the user to study all relevant engine
operating data, in short term trend mode, i.e. at very short intervals, over a
period of 2 weeks, and in long term trend mode, i.e. at longer intervals, over
several years, and thus to recognise developments and changes of operating
values long before they have an effect on the plant operation.
Diagnosis
Based on current readings taken during operation of the plant, the diagnosis
function provides the user with a clear analysis of defects and failures, which
symptoms lead to this conclusion (which operating figures are not as they
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24,8MW Gas Power Plant
Section 5 - Electrical scope
Item
Q’ty Description
should be) and which remedial measures should be taken.
CoCoS EDS, with its functions monitoring, trend and diagnosis, does not replace the engine alarm system. It is in fact subordinate to the engine alarm
system. However, due to its sensitivity in detecting and reporting occurrences,
it responds prior to the engine alarm system. Thus CoCoS EDS allows the user
to take the necessary countermeasures long before any serious defects or
failures appear. In this way, unnecessary stoppages of the engines can be
avoided, maintenance work reduced and availability of the plant increased.
To achieve these unique features, CoCoS EDS relies on performance graphs
which are generated by our engineers for each single engine at the place of
installation, whether in the power plant or on board a vessel. This way the real,
at site operating conditions are considered, which is not possible with performance graphs that are created on the test bed only.
As CoCoS EDS can be freely configured and extended, it is also possible to
include further plant auxiliaries in its functions.
070.090.015
1
070.090.060 -1
1
5.2
5.2.1
080.050.010 -1
2
Connecting cables between EDS-Databox and CoCoS-EDS Hardware
Optional equipment
Online Service Reporting
With Online Service PrimeServ provides a set of remote service product modules to enable an optimized engine operation. Thanks to effective data transmission via a secure IPsec protocol Online Service can transmit important engine and installation information throughout the world, can evaluate it and make
available the know-how of the MAN Diesel & Turbo PrimeServ experts in real
time. Main goal of Online Service is to support our customers globally. The
remote connection will be established via the remote access device in our
scope of supply. The Online Service portfolio contains small solutions like
online assistance with real time remote connection on demand as well as daily
data transfers including limit check, trend analysis and regular reporting.
The Online Service shall begin with TOC of the power plant and is limited to a
period of one year. Online Service shall be exclusively governed by the currently valid MAN Diesel & Turbo General Terms and Conditions on Online Services, available on our homepage.
Electric plant system
LV sub distribution
Engine Auxiliary Panel (EAP)
Purpose:
The Engine Auxiliary Panel (EAP) is the low voltage sub-distribution, the Motor
Control Center (MCC) for the power supply of the genset related auxiliaries and
for manual local operation of genset related auxiliaries which have no own control. It is the control part for the decentralized periphery, collecting all genset
related signals from the field, e.g. pipes, auxiliaries, modules and not genset
attached parts. The EAP is located in the mechanical annex of the genset area
in the engine hall.
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24,8MW Gas Power Plant
Section 5 - Electrical scope
Item
Q’ty Description
Properties:
The EAP consists of a fully enclosed metal cabinet in steel frame construction,
arranged for floor mounting with a plinth, totally closed and the front doors with
rubber gasket. The door lever is with a key. Cables insert from bottom through
plinth. Connection to the GCP for safety relevant signals and to the GIP/ECP
for the emergency stop of the auxiliaries.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 2000mm
− Height:
approx. 2200mm
− Depth:
approx. 600mm
The panels are equipped with fans, thermostat, air filters and anti-condensation
heating
AC 230 V UPS power supply input for generation of 24 V DC for control
With panel light and socket outlet (AC 230V)
− Panel protection degree
IP54
− Color / plinth color
RAL 7035 / RAL 7022
Hardware:
− Starters for genset related auxiliaries
− Power supply feeders for genset related auxiliaries
Control system:
− Siemens ET200M (collecting of signals from genset related auxiliaries, e.g.
modules and distribution of these signals to PLC Siemens SIMATIC S7-400
in the GCP)
080.050.020 -1
1
Common Auxiliary Panel (CAP)
Purpose:
The Common Auxiliary Panel (CAP) is the low voltage sub-distribution, the
Motor Control Center (MCC) for power supply of the plant related auxiliaries
inside the power house, which are not genset related and for manual local operation of the auxiliaries which don't have an own control. It is the control part
of the decentralized periphery, collecting signals from the different plant related
pipes sensors, auxiliaries and modules inside the power house. The CAP is
located centralized on the level of the mechanical annex of the power house.
Properties:
The CAP consists of a fully enclosed metal cabinet in steel frame construction,
arranged for floor mounting with a plinth, totally closed and the front doors with
rubber gasket. The door lever is with a key. Cables insert from bottom through
plinth. Connection to the CCP for control purpose.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 2400mm
− Height:
approx. 2200mm
− Depth:
approx. 600mm
The panels are equipped with fans, thermostat, air filters and anti-condensation
heating
AC 230 V UPS power supply input for generation of 24 V DC for control
With panel light and socket outlet (AC 230V)
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24,8MW Gas Power Plant
Section 5 - Electrical scope
Item
Q’ty Description
− Panel protection degree
− Color / plinth color
IP54
RAL 7035 / RAL 7022
Hardware:
− Starters for common auxiliaries located in power house
− Power supply feeders for common auxiliaries located in power house
Control system:
− Siemens ET200M (collecting of signals from auxiliaries in the power house
and distribution of these signals to PLC Siemens SIMATIC S7-400 in the
CCP)
080.050.050 -1
2
Engine Radiator Panel (ERP)
Purpose:
The Engine Radiator Panel (ERP) is the low voltage sub-distribution, the Motor
Control Center (MCC) for the power supply of the engine related auxiliaries and
for manual local operation of the auxiliaries, which don't have an own control.
The ERP is located in the radiator area, outside of the power house.
Properties:
The ERP consists of a fully enclosed metal cabinet in stainless steel frame
construction, arranged for floor mounting with a plinth, totally closed and the
front doors with rubber gasket. The door lever is with a key. Cables insert from
bottom through plinth. Connection to the GCP.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 2000mm
− Height:
approx. 2200mm
− Depth:
approx. 600mm
The panels are equipped with fans, thermostat, air filters and anti-condensation
heating
AC 230 V UPS power supply input for generation of 24 V DC for control
With panel light and socket outlet (AC 230V)
− Panel protection degree
IP54
− Color / plinth color
not painted
Hardware:
− Starters for radiators and radiator related auxiliaries
Control system:
− Siemens ET200M (collecting of signals from radiators and radiator related
auxiliaries and distribution of these signals to PLC Siemens SIMATIC S7400 in the GCP)
080.050.120 -1
1
Common PH Ventilation Panel (CVP)
Purpose:
The Common Ventilation Panel (CVP) is the low voltage sub-distribution, the
Motor Control Center (MCC) for the power supply of the power house ventilation. It is the control part for the decentralized periphery, collecting all powerhouse ventilation related signals and enables local control of the ventilation.
The CVP is located outside of the power house.
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24,8MW Gas Power Plant
Section 5 - Electrical scope
Item
Q’ty Description
Properties:
This panel consists of a fully enclosed metal cabinet in stainless steel frame
construction (Rittal TS) arranged for floor mounting without plinth, totally closed
and the front door with a rubber gasket. The door lever is with a key. Cables
insert from the bottom. Connection to the CCP for control purpose and safety
relevant signals.
Dimensions of each panel (Type Rittal TS):
− Width:
approx. 1200mm
− Height:
approx. 2200mm
− Depth:
approx. 600mm
The panels are equipped with fans, thermostat, air filters and anti-condensation
heating
AC 230 V UPS power supply input for generation of 24 V DC for controlWith
panel light and socket outlet (AC 230V)- Panel protection degree IP54
− Color / plinth color
not painted
Hardware:
− Starters for the power-house ventilation
− Power supply feeders for the power-house ventilation
Control system:
− Siemens ET200M (collecting of input/output signals and distribution of these
signals to PLC Siemens SIMATIC S7-400H in the CCP)
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24,8MW Gas Power Plant
Section 6 - Miscellaneous
6
Item
Miscellaneous
Q’ty Description
6.1
6.1.1
170.010.010 -1
3
Documentation
Basic plant technical documentation
Sets of genset and equipment documentation in paper edition
Consisting of:
Operating manual of delivered equipment
− General overview including residual risks
− Reference list of associated documents
Instruction manuals of engine and turbo-charger
− Operating instructions and maintenance schedule
− Working instructions
− Spare parts catalogue
− Tools and spare parts lists
− Workshop test acceptance certificate
Documentation of the genset including:
− Instruction manual of alternator, etc.
− Drawings
Set of manuals of delivered equipment
Additionally, the above mentioned documents will be handed over in PDFformat on CD or DVD. Publication of intermediate status of O&M manuals on
online platforms (on demand). The documentation will be in English language
and in MAN Diesel & Turbo's standard format.
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Section 7 - Tools, spare and wear parts
7
Item
Tools, spare and wear parts
Q’ty Description
7.1
7.1.1
Tools and spares
Engine tools
015.010.010
1
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 hydraulic bolt tensioning devices
DEVICES
− For the crankshaft bearing caps
Mounting and removing devices for:
− Cylinder heads with rocker arm casing
− Inlet and outlet valves
− Gas valves and gas pipes
− Pistons including insertion bush
− Cylinder liners
− Connecting rod bearing caps
− Connecting rods
− Camshaft vibration damper
015.010.020
1
Crank web deflection measuring device
015.010.080
1
Electric valve cone grinder
for the exhaust valves, make HUNGER
015.010.090
1
Electric valve seat grinder
for the inlet and exhaust valve seats (alternating current 230V)
015.010.182
1
Assembly and reversing device for the cylinder heads
7.1.2
015.020.020
2
Engine spare and wear parts
Set of engine standard spare parts
for engine type 20V35/44G, 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
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Section 7 - Tools, spare and wear parts
Item
Q’ty Description
Inlet valve:
− 1 Inlet valve, complete
Exhaust valve:
− 1 Exhaust valve, complete
Operation/Monitoring:
− 1 Three-way solenoid valve
− 1 Pressure reduction valve
Seals and round seal rings:
− 1 Set of seals and seal rings for 1 cylinder
Sealing material:
− 1 Set of sealing material
Gas operation:
− 4 round seal ring for gas valve
− 4 round seal ring for gas valve guide
− 4 gas valve
− 1 gas valve drive
− 4 prechamber insert
− 4 set of round seal rings for pre-chamber insert
015.020.070
1
Spare parts for operating and monitoring the engine
015.020.140
1
Set of spare parts for SACOS
7.1.3
015.030.090
1
7.1.4
015.040.020 -1
1
Plant tools
Mobile strainer cleaning unit
For lube oil automatic filter, consisting of:
− Tank
− High-pressure pump
− Pump protecting filter
− Microfilter
− Cleaning gun with high-pressure hose
− Cleaning liquid
Plant spares
Set of spare parts for alternator
consisting of:
− 1 Set of diodes; varistor (for one generator)
− 1 Pt100 for bearing
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Section 8 - Services
8
Item
Q’ty Description
8.1
205.010 -1
1
8.1.1
205.050 -1
Services
1
Quality Management, Quality Assurance
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 sub-suppliers.
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 supplied. Factory/Site Acceptance
Tests follow the individual items of this plan.
The electronic version of the documentation is consisting 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.
HSE Planning
Establishing of the necessary HSE Measures
MAN Diesel & Turbo has implemented a HSE Management System that conforms to OHSAS 18001, OHRIS and ISO 14001 standards. The integrated
quality and HSE management manual is applied to all internal process steps to
assure MAN Diesel & Turbo's grade of quality, safety for our people as well as
for the environment and others.
Individual activities for fulfilling the MAN Diesel & Turbo HSE standards as well
as the local requirements will be defined. The electronic version of the documentation should consist of:
− Risk assessment
− Adopted HSE-Manual and Site rules (in case of EPC or Consortia)
− Audit planning- Deviations of the MAN Diesel & Turbo standard (if applicable) The HSE Manual and the site rules will be handed over in PDF format
on CD/DVD. The documents will be in English language and in MAN Diesel
& Turbo standard format.Other Documents will be filed and handed in if
necessary.
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Section 8 - Services
Item
Q’ty Description
8.2
8.2.1
210.015.010 -1
1
8.2.2
210.020 -1
1
8.2.3
210.033.010
1
Project engineering
Process & Tender Engineering
System engineering
MAN Diesel & Turbo will engineer the offered scope of supply and provide 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
− Explosion protection systems (if applicable)
− 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 Diesel & Turbo will execute P&I Diagrams of all mediums required for the
offered scope of supply.
Mechanical project engineering
Mechanical project engineering
MAN Diesel & Turbo will execute following order drawings:
− Site plan showing the outdoor facilities of the power plant
− Power house layout drawing
Calculation of genset foundation
Design of the genset foundation base
Based on the genset foundation drawing mentioned above, MAN Diesel & Turbo will execute civil design works for the genset foundation.
As an outcome of the civil design works MAN Diesel & Turbo 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.
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Section 8 - Services
Item
Q’ty Description
8.2.4
210.040 -1
1
8.2.5
210.060 -1
1
8.2.6
210.066 -1
0
1
Engineering of auxiliaries
Engineering of auxiliaries
Based on the standard system engineering mentioned above, MAN will define
and engineer all offered equipment.
Electrical engineering
Electrical engineering
Establishing of the electrical documentation of the offered scope of supply,
consisting of:
− Technical specification of electrical equipment
− Electrical cabinet drawings
− PLC architecture / schematic diagrams
− List of measuring and control devices (plant)
− List of Electrical Consumers
Protection study
Protection study
Purpose:
The Protection Study serves for the calculation of the relevant short circuit currents to verify the correct design of the main electrical components in the power
plant. The Protection Study determines the setting values for the protection
devices of the electrical equipment.
Properties:
The protection study is the result of a protection engineering service. The study
indicates all input data which has been considered for the study. The study
based on the IEC 60909 standard for short-circuit calculation, data sheets of
the electrical components, requirements of MAN Diesel & Turbo (e.g. protection matrix, protection and measuring scheme), requirements of the grid operator or grid code and studies carried out by others. The protection study will be
done for all protection devices (e.g. protection relay of alternator, step-up and
station transformer) in the scope of supply of MAN. It provides the setting values for the main LV (Low Voltage) circuit breakers, depending on project specific arrangement. The results and setting values shall ensure the proper protection for the electrical equipment under all operation modes. The study verifies that faults of electrical equipment (e.g. short circuit, earth fault) will be disconnected in a safe manner, in sufficient time and selective.
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Section 8 - Services
Item
Q’ty Description
8.2.7
210.070 -1
1
8.3
8.3.1
Basic civil engineering
Basic civil engineering
Assistance for preparation of:
− Site layout proposal
− Layout proposal power house
− Layout proposal ancillary buildings/tank farm
Logistics
Transportation of equipment
The engine will be transported completely assembled and mounted on the
foundation frame.
220.020.010
1
Transport of engines to FOB any Port in Europe
220.020.040
1
Transport of auxiliaries to FOB any Port in Europe
8.4
8.4.1
Site activities
Supervision of installation
230.030.040 -1
47 man days Supervision of genset and mechanical equipment installation
This service includes placing of the engine with springs elements on the foundation, coupling and alignment with the alternator, grouting of alternator, as
well as placing all the mechanical equipment supplied by MAN Diesel & Turbo.
The following prerequisites are necessary:
− All engines and alternators are already unpacked and prepared for placement.
− The auxiliaries are at site, unpacked and prepared for placement
− Power house crane is available and the roof is closed
− Hydraulic jacks, lifting devices, hydraulic tools, etc. are available
− Supervision as per MAN Diesel & Turbo quality standard.
230.030.060 -1
20 man days supervision of electrical installation
8.4.2
230.110.010 -1
Commissioning
36 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.
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Section 8 - Services
Item
Q’ty Description
230.110.020 -1
36 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 manufacturer's 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.
230.110.030 -1
22 man days commissioning of auxiliaries by technician
The technician will assist the commissioning engineer in performing all mechanical and electrical pre-tests and starting up of the individual components
and auxiliary systems.
230.110.035 -1
22 man days commissioning of auxiliaries by engineer
The commissioning engineer will perform all mechanical and electrical pre-tests
and starting up of the individual components and auxiliary systems.
230.110.040 -1
40 man days commissioning of LV / control equipment
The electrical commissioning engineer will verify the correct electrical installation of MAN Diesel & Turbo's scope of supply. He will perform the testing of
engine and plant related sensors together with the mechanical commissioning
engineer. He verifies the correct function of the engine control and safety system.
230.110.200 -1
10 man days commissioning alternator
One commissioning engineer from the manufacturer will commission the alternator according to the manufacturer's instruction. He will check the correct
installation as well as the function of the alternator protection and control system.
230.110.220 -1
2
man days commissioning cooling system
One commissioning engineer will verify the correct installation and set the cooling system into operation according to manufacturers instruction.
230.110.240 -1
1
man days commissioning powerhouse ventilation
One commissioning engineer will verify the correct installation and set the
power house ventilation into operation according to manufacturers instruction.
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Section 8 - Services
Item
Q’ty Description
8.4.3
230.120.010
1
Site Acceptance Test (SAT)
Performance test
Specialists from MAN Diesel & Turbo will perform measurements to demonstrate the guaranteed values. The measurements will be done by MAN Diesel
& Turbo 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 gas consumption:
Measurements and calculations of the fuel gas consumption will be carried
out in line with ISO 3046, ISO 15550 and MAN Diesel & Turbo standard
procedures.
− 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 Diesel & Turbo standard
procedures (engine running in). Due to the required measuring time being
minimum 72 hours, lube oil consumption measurement will continue after
the fuel consumption test.
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Section 8 - Services
Item
Q’ty Description
8.5
8.5.1
240.010 -1
1
Project services
Mechanical Training at PrimeServ Academy
Optional service
Mechanical Training at PrimeServ Academy
Advanced mechanical training course for 10 plant operators at the PrimeServ
Academy. Duration of the training is 15 days, training without traveling expenses, boarding and lodging. The training language will be English.
Seminar content:
Standard maintenance (5 days)
− Engine design and engine data
− Handling manuals
− Systems on engine
− Engine and turbocharger operation
− Basic maintenance tasks up to 6,000 hour service
− Hydraulic tensioning equipment
Advanced maintenance (5 days)
− Quality requirements of operating fluids
− Overhaul and replacement of sub-assemblies
− Turbocharger maintenance overview
− Engine maintenance tasks up to 32,000 hour service
Combustion system of the gas engine (2 days)
− Gas operation
− Gas safety
Introduction to engine control system (3 days)
− SaCoSone basics
− Device manager
− Expert tool
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
Q’ty Description
8.5.2
240.020 -1
1
On-Site training (mechanical)
Optional service
On-Site Training (mechanical)
Mechanical on-site training for your engineers and operators covering the essential elements of the Gas engine power plant. Duration is 10 days. The training language will be English. The course includes theoretical training as well as
field exercises.
Seminar contents:
− Welcome and general introduction
− Introduction to the Diesel power plant
− Design and basic operating principles of the specific plant
− Explanation of the auxiliary systems and review of piping and installation
drawing
− Routines in normal operation and symptoms/reactions to unplanned situations
− Engine start and stop procedures
− Engine operation
− Measuring and logging of data
− Control system design
− Mechanical maintenance
− Maintenance philosophies, planning, reporting, spare part ordering
− Planning of major overhauls
− When equipment accessible: measuring crank web deflection, adjusting
valve clearance, testing of injectors, hydraulic tensioning tools
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. In order to achieve the best possible learning
results, the max. number of participants per class is limited to 10 persons.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.
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Section 9 - Requirements and limitations
9
9.1
Requirements and limitations
Quality requirements for operating media
MAN engines are designed for continuous operation on the operation media as
listed below. Project-specific system layouts for the respective operating media
are mentioned in the respective chapters of our offer.
9.1.1
Lube oil
Use of engine lube oils according to the Approval List for Gas Engines 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°)
SAE 40
Requirements for Base Number (BN):
− TBN (Total Base Number)
min. 5 mg KOH/g oil
Please note that our cooling systems are designed to operate with the abovementioned lube oil class SAE 40 only. Operation of the plant with other lube oils
requires a detailed modification in the cooling systems and additional equipment
cost.
9.1.2
Engine cooling water
The engine 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 operation the concentration
specified by the engine manufacturer must always be ensured. The approved
cooling water additives are defined in the operating instructions.
The characteristics of the water used for engine cooling must be within the following limits:
− Type of water
Distillate or freshwater,
free from foreign matter
9
− Total hardness
< 6 °dH
− pH-value
> 6.5
− Chloride (Cl)
< 50 mg/l
− TSS
< 10 mg/l
Seawater, brackish water, brines, industrial waste water and rain water cannot
to be used without treatment.
9.1.3
Raw water quality for fresh water
The raw water used should match the following values, before being treated in
the water treatment system. If the water quality is different from the values stated below, the water treatment system will have to be modified at an extra cost.
9
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
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
9.1.4
pH value at 25°C
Conductivity at 25°C
Hardness
TDS (Salinity)
Chloride (Cl)
Sulfate (SO42)
TN (NO2-, NO3-, NH4+)
Calcium
Magnesium
Sodium
Potassium
Silicate
Iron (Fe)
Manganese (Mn)
Copper (Cu)
Oxygen (O2) Dissolved
Turbidity
Fecal coliform
7.7
511 µS/cm
6 °dH
380 mg/l
45 mg/l
24 mg/l
1 mg/l
19.1 mg/l
14 mg/l
100 mg/l
2 mg/l
6 mg/l
0.01 mg/l
0.01 mg/l
0 mg/l
2 mg/l
1 NTU
0 / 100 ml
Natural gas
The following fuel specification must be met at the intake of the gas control unit.
− Dust
max. 0.05 g/Nm³
− Hydrogen sulfide (H2S)
max. 5 mg/Nm³
− Tar
max. 0.5 g/Nm³
− Fluorine
max. 5 mg/Nm³
− Chlorine
max. 10 mg/Nm³
− Relative humidity
max. 80 %
− Temperature
5 .. 50°C
− Gas operating pressure
9.5 … 10.5 bar(g)
− Max supply pressure
16.0 bar(g)
− Fluctuations in gas pressure
max. 1.5% of gas pressure
The temperature- and pressure-dependent dew point of natural gas must always be exceeded to prevent condensation.
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Section 9 - Requirements and limitations
9.1.5
Intake air
The quality and condition of intake air (combustion air) have a significant effect
on the power output of the engine output as well as on the engine's lifetime. In
this regard, not only the atmospheric conditions are extremely important, but
also contamination by solid and gaseous foreign matter. Mineral dust in the
intake air increases wear, chemicals and gases promote corrosion.
The concentrations before the turbocharger inlet must not exceed the following
limiting values:
− Particle size
90% ≤ 5 µm; 98% ≤ 10 µm
− Dust (sand, cement, CaO, Al2O3 etc.)
max. 5 mg/Nm³
− Chlorine
max.1.5 mg/Nm³
− Sulfur dioxide (SO2)
max.1.25 mg/Nm³
− Hydrogen sulfide (H2S)
max.5 mg/Nm³
− Salt (NaCl)
max.1 mg/Nm³
If combustion air is drawn from inside the powerhouse, the minimum required
filter class is G3 according to EN779 or equivalent. Gas engines or dual-fuel
engines must be equipped with a dry filter. If the combustion air is drawn from
outside, there is a risk of higher air contamination (e.g. due to sand storms,
loading and unloading of grain cargo vessels or a cement plant). In this case
additional measures need to be taken. This includes the use of pre-separators,
pulse filter systems and an increased filter efficiency class of M5 according to
EN779.
The offered intake air filter unit meets the requirements for separation of particles in new condition. During operation, effective cleaning of the intake air and
regular maintenance of the air filters are required to stick within the abovementioned limits.
Intake air shall not contain any flammable gases. Make sure that the combustion air is not explosive.
9.1.6
Compressed air
The compressed air systems are divided into a starting air system -- used to
start the engines, a control air system -- for auxiliary systems and a service air
system – used for tools and working equipment.
Requirements for starting air:
− Pressure
30 bar(g)
Requirements for control air:
− Water
ISO 8573-1 – Class 2
− Particles
ISO 8573-1 – Class 2
− Oil
ISO 8573-1 – Class 2
− Pressure
7 bar(g)
Requirements for service air:
− Water
ISO 8573-1 – Class 4
− Particles
ISO 8573-1 – Class 4
− Oil
ISO 8573-1 – Class 4
− Pressure
6 bar(g)
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Section 9 - Requirements and limitations
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 is supplied largely modularized. Necessary bolts, studs or screws
to install the equipment on the foundations or elevated platforms / walkways are
included.
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 steel spring elements including necessary erection material
− Grouting material for the alternator basement (Pagel)
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. gas, lube oil, water, 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
− SaCoSone panel connectors for data transfer (bus cables)
− SaCoSone panel connectors for power supply
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Section 10 - Standards and Guidelines
10
Standards and Guidelines
10.1
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 Organization
− IEC International Electro technical Commission
− EN standard - European Institute for Standardization
− Manufacturer’s QA/QC System
− Manufacturer's standards
MAN Diesel & Turbo advises that national and/or local regulations may differ
from the abovementioned standards or guidelines. The national and/or local
standards are not considered in our bid. Compliance to national regulations and
standards are the sole responsibility of the customer or operator of the plant.
10.2
General guidelines
10.2.1
Mains water
supply and
water treatment
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.
10.2.2
Painting of the supplied equipment
Auxiliary equipment is delivered in the original color as supplied by the sub supplier, unless otherwise specified in this document.
10.2.3
Miscellaneous
Anything not specifically mentioned in the quoted scope is not included.
Minor changes due to technical development, design and output are reserved.
Other than the performances guarantees, all figures stated in this specification
such as pressures, capacities, flows etc. are preliminary only and subject to
change during detailed engineering phase.
10.2.4
Required information from the customer
In case of order the customer shall supply to MAN Diesel & Turbo with the following documents and information in due time:
− Current site plan and arrangement drawing showing the exact location and
dimension of the area of the power plant and the neighboring installations
− The prevailing wind direction, indicating the value of the basic wind velocity
− Geotechnical report with information on the minimum capacity of the existing
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Section 10 - Standards and Guidelines
foundation soil, the presence of groundwater, recommendations for piling
− Information on the reference peak ground acceleration for construction of
buildings according to definition as defined in footnote 2, including soil type
or value for share wave velocity
− Minimum load bearing capacity of power plant subsoil or soil investigation
report
− List of electrical consumers to be provided locally by customer
− Sample of gas fuel, raw water
10.2.5
Minimum requirements for personnel on site
The customer as well as MDT needs to ensure that adequately qualified personnel will be available for the site activities.
The customer shall send engineers/technicians to site who are well conversant
with the English language to avoid difficulties in communication with MDT engineers/technicians.
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Section 11 - List of sub suppliers
11
List of sub suppliers
This list includes a selection of the major equipment components and the respective vendors selected and approved by MAN Diesel & Turbo. This list may
not be complete. Above that MAN Diesel & Turbo at any time reserves the right
to select the vendor who is the most favorable one with respect to technology,
quality, delivery time, reliability or price in any individual case. Further vendors
may be included in the list following the completion of a vendor assessment.
MAN Diesel & Turbo reserves the right to deliver components manufactured in
any of the worldwide production facilities of the respective suppliers.
Generating set
Alternator
Flexible coupling
ABB, Jeumont, TDPS
Centa, Vulkan
Lube oil system
Lube oil module
GenSys, Alfa Laval, Kral,
W+Z Rohrsystem-Technik, GEA Westfalia Separator
Lube oil flow rate measuring device
Endress & Hauser, Bopp & Reuther
Lube oil transfer pump
Kracht, Rickmeier, Leistritz
Cooling water system
Cooling water pre-heater set
Radiator cooling system
Fuel system
Gas control line
Intake air system
Intake air filter unit
Compressed air system
Starting air compressor
Starting air receiver
Exhaust gas system
Expansion joint for exhaust gas
Others
Power house ventilation system
Elwa, Zoppas
Ecodyne, Alfa Laval Vantaa, Thermofin,
Lu-Ve, Friterm
GenSys, RMG Regel+Messtechnik Honeywell
AAF International, IAC, GEA Air Treatment
Sauer & Sohn, Sperre Industri AS
Atlas Copco, VPT, Neuenheuser, Kaeser
Römer, Neuenhäuser
Eagle Burgmann, Stenflex, Witzenmann, HKS
GEA Air Treatment, Robertson Vogue,
AAF International
Our Reference 5303129-01-B001
5303129_24,8MW Gas Power Plant_2x20V3544GTS_Technical Specification_Rev0.docx
Page 47 of 48
24,8MW Gas Power Plant
Section 12 - Drawings
12
12.1
Drawings
Drawing of the generating set 11.74500-1847
Our Reference 5303129-01-B001
5303129_24,8MW Gas Power Plant_2x20V3544GTS_Technical Specification_Rev0.docx
Page 48 of 48
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