Diesel Power Generation Plants with Multiple Machines in Parallell and on the Electrical Power Grid

Technology Training that works

Diesel Power Generation Plants with Multiple Machines in Parallel and on

the Electrical Power Grid

Technology Training that Workswww.idc-online.com/slideshare

Learning objectives

• Industrial applications• Power generation plant applications• Essential subsystems in a Engine based power plant • Single and multiple sets• Fuel storage requirements• Air Intake system• Exhaust system• Auxiliary power requirements• Typical power schemes • Typical power plant layout


Application of Diesel Generators in Industry

• Mainly used for emergency power assistance• Loads will typically consist of:

– Critical drives– Battery charges/UPS equipment– Emergency lighting– Safety related equipment (fire fighting, cooling water)

• Any other facility requiring power without long interruption if mains power fails


Application of Diesel Generators in Industry• Supplementing regular power source• Areas with weak grids of inadequate capacity• Unreliable power supply• Aim is to continue with production to full capacity• Shortfall from external power source is made up• Base load operation (in parallel with grid) is NOT the objective in

such a case


Power generation applications• Non-industrial power generation application for small

towns and communities• Lack of other resources

– Hydro-electric power or other means is not possible

• Long distance from existing grid resources– Uneconomical to establish T&D infrastructure

• Small capacity requirements– Thermal /nuclear generation unviable for such capacity

• Multiple generators for reliability


Power plants using Diesel Generation

• A power plant contains all essential facilities for operation and supply of power

• Main component is naturally the engine-generator• Will also include other facilities such as:

– Fuel storage, cooling equipment, lubrication systems, auxiliary ac and dc power, switchgear for generator and auxiliaries, minor repair and maintenance facilities

– Control and instrumentation of the engine– Synchronising facility where needed– Associated power off take/distribution switchgear


Engine generator

• Usually supplied as a complete unit• A common base-frame/skid with engine generator

and mounted auxiliaries• Sometimes portable units for small capacities• Can be complete with generator control,

switchgear• Requires hook up to external facilities located

outside the base-frame


Typical Portable Generator Set


Layout of a small DG installation


Layout of a large DG installation


Salient aspects of large DG plants• Heat recovery boiler located on roof as a part of the stack

system• Feed water tank for boiler• Overhead crane in DG hall (Electrically operated where

required)• Heat exchangers/cooling towers outside the building (one

for each unit) for radiator water cooling• Air filter at intake point with silencer• Fuel treatment plant and fuel circulation system• Lube oil tank below grade level


Fuel storage system-Typical


Fuel storage-salient features• Storage capacity of 15 days to 30 days of consumption• Metal storage tanks (separate for each fuel) for fuel and lube

oil• Tank farm with dyke for containment• Local codes for flammable/explosive substances to be adhered

to• Truck unloading and receiving arrangement with measuring

facility• Fire hydrants and foam type extinguishers


Air intake• For combustion air to the engine• Intake filter facing outside• Oil wetted filters for large ratings

– Viscous oil used captures fine dust

• Silencers required to limit noise to 40 dB (A) as air velocity can be high

• Compressor unit of Turbocharger at intake point with an after cooler

• Isolation using bellows between intake system and turbocharger


Exhaust system components• Turbo-charger (recovers exhaust gas energy)• Ducting from engine exhaust with expansion bellows• Silencer• Waste heat recovery boiler• Chimney • Exhaust gas quality measurement devices• Lightning protection/aviation obstruction lights for

chimney


Typical exhaust system

Plan view

Section


Auxiliary power system• Auxiliary power is about 3 to 4% of DG output• Main auxiliaries

– Lube oil pump– Engine cooling water pumps – Fuel injection pumps

• Auxiliary source: DG Plant power• Auxiliary transformer for HV alternators• Redundancy for aux. power to meet failures


Auxiliary loads (Fuel system)

• Fuel oil unloading pumps• Fuel oil separators or purifiers• Fuel oil transfer pumps• Fuel oil Booster pumps• Return oil pumps• Lube oil unloading pumps• Lube oil separator units• Pre lube oil pumps• Sludge transfer pumps• Oily water transfer pumps


Other auxiliary loads• Starting air compressor• Instrument air compressor• DG hall ventilation system consisting supply and exhaust fans• Plant water system motors• Plant lighting loads• Workshop Equipment Loads• Air conditioning loads for control room• Switchyard equipment and Plant HT and LT switchgear power requirement


Important aspects in planning• What is the objective of the generation?• What will be the voltage of the generators?• Generator location and hook up with the system• What is the capacity requirement?• Multiple generators to be provided? (Synchronising and load

sharing)• Sizing of generator units• Special conditions to be looked at (de-rating may be necessary)

– Large drives to be started on the generator– High non-linear load component– Unbalanced loads to supplied


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Engineering

Diesel Power Generation Plants with Multiple Machines in Parallell and on the Electrical Power Grid