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# 210 MWnet COAL FIRED POWER PLANT, MINDANAO, PHILIPPINES

## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

CONTENTS

CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 ATTACHMENT ANNEXURE - 1

DESCRIPTION PURPOSE SIZING CRITERIA LEGEND FORMULAE USED EQUIPMENT DATA SIZING CALCULATION FINAL SIZING OF DG SET

STATION AUXILIARY BASE LOAD DURING SAFE SHUT - DOWN & STANDSTILL CONDITIONS SINGLE LINE DIAGRAM - EMERGENCY DG SET

ANNEXURE - 2

## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

1.0 PURPOSE The purpose of this calculation is to determine the sizing of Emergency Diesel Generator Set for catering the loads during safe shut-down & standstill conditions of the power plant. 2.0 SIZING CRITERIA The sizing of Emergency DG Set will be such that it should cater the maximum of load requirement of the following two cases during safe shut-down & standstill conditions : Case -1 (Load Criteria) - The sum of the following loads : a) Station Base Input Loads as per enclosed Annexure - 1, except Fire Water Pump Motor (largest motor) b) Running Load of Fire Water Pump Motor (largest motor) Case - 2 (Voltage Drop Criteria) - The sum of the following loads : a) Station Base Input Loads as per enclosed Annexure - 1, except Fire Water Pump Motor (largest motor) b) Starting Load of Fire Water Pump Motor (largest motor) 3.0 LEGEND Refer Electrical Single Line Diagram given in enclosed Annexure - 2 Eg VLV VMS Ig Ib Xdg' Rg Zg ZC1 ZC2 ZLV ZMS ZEL = EMF generated in DG Set = Voltage at Bus of 480V Emergency Switchgear = Voltage at terminal of largest motor during starting = Current through DG Set = Current through Station Base Loads = Transient Reactance of DG Set = Resistance of DG Set = Impedance of DG Set = Impedance of Cables between DG Set and 480V Emergency Switchgear = Impedance of Cables between 480V Emergency Switchgear and largest motor = Impedance of Station Base LV Loads = Impedance of largest motor during starting condition = (ZC2+ ZMS ) II ZLV

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

4.0 FORMULAE USED a) Base = Base kV2 / Base MVA Impedance (in ohms) Per Unit = Impedance in ohms / Base Impedance in Ohms Impedance (in p.u.) Zp.u.-new = Zp.u.-old x MVAbase-new / MVAbase-old x (kVbase-old / kVbase-new ) 2 Load = Base MVA / Load MVA x (Load Voltage / Base Voltage)2 Impedance (in p.u.) Load = Base MVA / Load MVA x (Load Voltage / Base Voltage)2 x Cos , Resistance where Cos = load power factor (in p.u.) Load = Base MVA / Load MVA x (Load Voltage / Base Voltage)2 x Sin Reactance (in p.u.)

b)

c) d)

e)

f)

5.0 EQUIPMENT DATA a) DG Set Rating Voltage Xdg' Xdg' / Rg Rg b) Fire Water Pump Motor kW Rating (largest motor) Voltage Rating Running p. f. Efficiency Full Load Current Starting / Full Load Current Starting Input kVA Starting p. f. Starting Input kW Starting Input kVAR Cable C1 Size No. of run Length Resistance per run Reactance per run Total Resistance Total Reactance Size No. of run Length Resistance per run Reactance per run Total Resistance Total Reactance = = = = = = = = = = = = = = = = 1250 0.48 14.00 0.14 23.00 0.0061 150.00 0.46 0.85 0.930 238.16 6.0 1138.52 0.25 284.630 1102.367 kVA (assumed) kV % on its own base (assumed) p.u. on its own base (as per IEEE) p.u. on its own base kW kV

## Amps 5 times with IEC tolerance (+20%) kVA kW kVAR

c)

= 1C-500 mm2, XLPE = 4 = 110.00 Meters = 0.0543 Ohms / kM = 0.0948 Ohms / kM = 0.0015 Ohms = 0.0026 Ohms = 3C-240 mm2, XLPE = 2 = 275.00 Meters = 0.0998 Ohms / kM = 0.0943 Ohms / kM = 0.0137 Ohms = 0.0130 Ohms

d)

Cable C2

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

6.0 SIZING CALCULATION 6.1 Calculation for Impedances Let, Base kVA Base kV Base Impedance a) = = = 1250 kVA 0.48 kV 0.1843 Ohms

Station Auxiliary LV Input Base Loads except largest motor (Refer Annexure - 1) Rated Voltage = Loads in kW = Loads in kVAR = Loads in kVA Power factor During pre-start condition of largest motor, the terminal voltage at all loads assumed in terms of rated voltage Real part of impedance of these loads Imaginary part of impedance of these loads ZLV, during pre-start condition of largest motor, During starting condition of largest motor, the terminal voltage at all loads assumed in terms of rated voltage Real part of impedance of these loads Imaginary part of impedance of these loads ZLV, during starting condition of largest motor, impedance in p. u. = = =

460 V 644.822 kW at 460V 437.632 kVAR at 460V 779.306 kVA at 460V 0.8274 0.95 > 0.90 as per specification

= 1.1001 p. u. = 0.7466 p. u. = 1.10005487270052+0.746592500578708j = = = = 0.89 > 0.75 as per specification 0.9655 p. u. 0.6553 p. u. 0.965488603508128+0.65526417696221j

b)

## DG Set Rg Xdg' Zg = 0.0061 p. u. = 0.1400 p. u. = 0.00608695652173913+0.14j

c)

Fire Water Pump Motor Real part of impedance during starting condition Imaginary part of impedance during starting condition ZMS 0.2521 p. u. = = 0.9763 p. u. = 0.252082429108796+0.97631104980988j

d)

Cable C1 Real part of impedance Imaginary part of impedance ZC1 = 0.0081 p. u. = 0.0141 p. u. = 0.00810139973958333+0.0141438802083333j

e)

Cable C2 Real part of impedance Imaginary part of impedance ZC2 = 0.0744 p. u. = 0.0703 p. u. = 0.0744493272569444+0.0703464084201389j

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

6.2 Calculation for Sizing of DG Set for Case - 1 a) 1) Calculation for Sizing of Generator Station Input Base kW Loads Station auxiliary LV input base loads except largest motor = (Refer Annexure - 1) Running load of largest motor = Total of above items With 15% margin Total kW requirement 2) Station Input Base kVAR Loads Station auxiliary LV input base loads except largest motor = (Refer Annexure - 1) Running load of largest motor = Total of above items With 15% margin Total kVAR requirement 3) Required Rating of Generator kVA rating Voltage Power factor kW rating of Generator = = = = > = > 1250 kVA 0.48 kV 0.80 1000.000 kW 908.481 kW 750.000 kVAR 606.735 kVAR = = = 437.632 kVAR 89.963 kVAR 527.595 kVAR 79.139 kVAR 606.735 kVAR = = = 644.822 kW 145.161 kW 789.984 kW 118.498 kW 908.481 kW

## kVAR rating of Generator

b)

Calculation for Sizing of Diesel Engine Total requirement for station input base kW loads including largest motor Considering efficiency of Generator Required rating of Engine = 908.481 kW

= =

0.95 956.296 kW

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

6.3 Calculation for Sizing of DG Set for Case - 2 a) 1) Calculation for Sizing of Generator Motor Pre - start Condition Refer Equivalent Circuit - 1 of enclosed Annexure - 2 Let at this condition the voltage at Bus VLV ZLV in p. u. Ib = Ig = VLV / ZLV in p. u. (Zg + ZC1) in p. u. Ig*(Zg + ZC1) in p. u. Eg = VLV + Ig*(Zg + ZC1) in p. u. = 0.48 kV with angle Zero = 1 p. u. = 1.10005487270052+0.746592500578708j = 0.622371570056748-0.422395244372744j = 0.0141883562613225+0.154143880208333j = 0.0739400715120456+0.0899416745296506j = 1.07394007151205+0.0899416745296506j = 1.07769976 (within 10% range of AVR control)

2)

Motor Starting Condition Refer Equivalent Circuit - 2 of enclosed Annexure - 2 Eg in p. u. (Zg + ZC1) in p. u. ZLV in p. u. ZMS in p. u. (ZC2+ ZMS) in p. u. (ZC2 + ZMS)*ZLV in p. u. (ZC2 + ZMS + ZLV) in p. u. ZEL = (ZC2 + ZMS)*ZLV / (ZC2+ ZMS + ZLV) in p. u. (Zg + ZC1+ ZEL) in p. u. Ig = Eg / (Zg + ZC1+ ZEL) in p. u. Ig*(Zg + ZC1) in p. u. VLV = Eg - Ig*(Zg + ZC1) in p. u. = 1.07394007151205+0.0899416745296506j = 0.0141883562613225+0.154143880208333j = 0.965488603508128+0.65526417696221j = 0.252082429108796+0.97631104980988j = 0.32653175636574+1.04665745823002j = -0.370574448473838+1.22450041028489j = 1.29202035987387+1.70192163519223j = 0.351569291653108+0.48463402435267j = 0.36575764791443+0.638777904561003j = 0.83101026610059-1.20541381549433j = 0.197597832489279+0.110992306253151j = 0.876342239022771-0.0210506317235004j = 0.87659503 p. u. 420.7656 V 91.47 of rated voltage, which is as per assumption = and acceptable > 75 % as per specification

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## ZMS / (ZC2 + ZMS) in p. u. VMS = VLV*ZMS / (ZC2 + ZMS) in p. u.

= 0.918528030130026+0.0457132765495565j = 0.805907203878842+0.020724879834526j = 0.80617364 p. u. = 386.9633 V = 84.12 % of rated voltage, which is acceptable > 80 % as per specification

3)

Required Rating of Generator It is observed from the above calculation, the voltages available at LV load bus and largest motor during pre-start and starting conditions of this motor are within acceptable ranges. Required rating of Generator kVA rating = Voltage = Power factor 1250 kVA 0.48 kV 0.80

4)

Calculation for Sizing of Diesel Engine Station Auxiliary LV input base loads except largest motor = (Refer Annexure - 1) With 15% margin Starting load of largest motor Total of above items Considering efficiency of Generator Maximum short time kW demand on Engine Considering overloading capacity of Engine Required rating of Engine = = = = = = = 644.822 kW

## 96.723 284.630 kW 1026.176 kW 0.95 1080.185 kW 1.1 981.986 kW

7.0 FINAL SIZING OF DG SET 7.1 Selection of Generator Rating kVA rating of Generator will be the maximum of the calculated kVA ratings for the above Cases 1 and 2 Therefore, calculated maximum kVA rating of Generator 7.2 Selection of Engine Rating kW rating of Engine will be the maximum of the calculated kW ratings for the above Cases 1 and 2 Therefore, calculated maximum kW rating of Engine = 981.986 kW = 1250 kVA

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

7.3 Selection of DG Set Rating (Minimum) Selected rating of Engine Selected rating of Generator kVA rating Voltage Power factor Xdg' = = = = 1250 kVA 0.48 kV 0.80 14.00 % on its own base (without any positive tolerance) 10 % = 1000 kW

AVR Range = 7.4 Special Requirement for Fire Water Pump Motor Starting / Full Load Current at rated voltage =

## 5 times with IEC tolerance ( 20%)

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## Calculation of Emergency DG Set Doc. No. 13002 - Y1F001 (Rev. 2)

ANNEXURE - 1 STATION AUXILIARY BASE LOAD DURING SAFE SHUT - DOWN & STANDSTILL CONDITIONS Rating kW 11.00 65.00 45.00 75.00 p. f. 0.84 0.81 0.85 0.81 Efficiency 0.907 0.925 0.915 0.926 0.898 0.886 0.910 0.814 0.858 0.886 0.900 0.873 0.873 0.870 0.870 No. of Running Unit 2 2 2 2 2 2 1 2 6 2 1 1 1 2 1 2 3 Input Load Requirement kW 24.256 140.541 98.361 161.987 12.249 33.860 24.176 1.843 1.748 15.801 100.000 20.000 66.667 5.040 0.458 6.897 2.586 716.469 = = 1 = = 0.90 644.822 161.290 0.90 145.161 89.963 437.632 99.959 kVAR 15.668 101.750 60.958 117.277 7.268 20.091 15.616 1.382 1.311 9.376 88.192 Input rating 15.000 Input rating 21.912 3.518 0.320 4.814 1.805 486.258

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Load Description Turning Gear for Turbine Turbine Lube Oil Pump Emergency CCW Pump Auxiliary Cooling Water Pump Stand-by Motor for Rotor Drive Unit (GAH) Scanner Cooling Air Fan Jocky Pump Lube Oil Pump for Gas Air Preheater (GAH) Sector Plate Drive Unit for GAH Elevators Plant DC / UPS System 138kV Switchyard AC Emergency Lighting Load Ventilation fan for Battery Room Fuel Oil Pump for Emergency DG Main Cooling Water PumpDischarge Valve Other Valve Total

Remarks

5.50 0.86 15.00 0.86 22.00 0.84 0.75 0.80 0.25 7.00 100.00 20.00 60.00 2.20 0.40 0.80 0.86 0.75 0.80 0.95 0.82 0.82

## 3.00 0.82 0.75 0.82

Considering overall load factor Total Input LV Load Requirement except Fire Water Pump Motor (largest motor) Fire Water Pump Considering overall load factor Input LV Load Requirement for Fire Water Pump Motor (largest motor) NOTE : 1) 2) a) b) 150.00 0.85 0.930

For the list of loads during safe shut-down & standstill conditions of the power plant, refer Doc. No. 13002 - A0G301 - Sizing Critera of Emergency Diesel Generator. The following loads have been envisaged to be fed Plant DC / UPS System : Plant DC load including DCS load at 125V DC Plant UPS System consisting of loads of the following items at 120V, 1 Ph, AC : - DCS Load - Turbine Control system - Communication Systems, consisting of Telephone System, Paging System with Radio Paging and Voice Recordind System - Server / PC Network in Administration Building - Fire Alarm Panel
- Siren - Emmission Monitoring System

3) No. and rating of drives, listed above, are preliminary and indicative only. The same will be revised based on the final load list.

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## ANNEXURE - 2 SINGLE LINE DIAGRAM - EMERGENCY DG SET Eg Eg

Zg Emergency DG Set 1250 kVA, 480V, 0.8 p.f., Xdg' = 14% ZC1 480V Emergency Switchgear Cable C1 480V Emergency Switchgear 480V Emergency Switchgear

Zg

ZC1

VLV

VLV

Cable C2

ZLV Station Auxiliary LV Input Base Loads at 460V (Lump Loads except largest motor) Fire Water Pump Motor 150kW, 460V (Largest Motor)

ZLV

VMS

ZMS

## EQUIVALENT CIRCUIT - 2 MOTOR START CONDITION

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