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Operation of Diesel Power Plant

Article February 2012

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Priyanka M M
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Operation of Diesel Power Plant


Priyanka Mankale1 Student Member IEEE , Sunita Tambakad2 Member IEEE and Jangamshetti S.H3 Senior Member IEEE

auxiliaries are monitored & controlled by a PLC system


Abstract: The diesel power plant is designed for base load
located in the Control Room.The heavy fuel oil received
operation for stationary application and is intended for
through tankers are unloaded through a pumping station &
electricity production in parallel operation with a public
stored in two 7000m3 capacity storage tanks. Similarly the
supply as well as island mode operation. This paper
fresh lube oil received from tankers is also stored in New Lube
presents the case study of Tata diesel power plant. The
oil tank of 50 m3 capacity. Hidkal dam located 50 kM from the
capacity of the plant is 81.3MW. The power plant is equipped
plant is the chief source of water. The water received from
with five generating sets consisting of a WATSILA 18V46 as
Hidkal dam is stored in an open reservoir of 10000 m3
prime mover driving a three phase brushless, self cooled,
capacity. The entire Plant is protected from fire by a protection
synchronous, ABBAMG 1600SS12DSEB generator. The
system & fire hydrant pipelines are systematically laid to
capacity of each DG is 16.26MW. The plant is designed for
cover all important locations & equipment. The engine room
operating on heavy fuel oil (HFO) with light fuel oil (LFO)
is equipped with Ultra Violet / Infrared fire detection
as standby fuel. The fuel is being received by road tankers
equipments which sends signal to the Control room. The
from the nearest oil terminal of Indian Oil Corporation Ltd
Control room is equipped with Hot Line facility to interact
(IOCL). Annual consumption of HFO for the plant would
with the Citys Fire tenders in case of eventualities. This paper
be around 0.110 million tones. The power plant in the field
gives detailed description of the Tata diesel power plant. It
of power generation and distribution maintaining eco
explains essential elements of diesel power plant like diesel
friendly environment by adopting green belt design as per
engine(DG) set, fuel system, lubrication system, cooling
the guideline of Karnataka State Pollution Control Board
system, compressed and exhaust system. The processing of
(KSPCB). By following generally recognized diesel
each system and technical features of electrical equipments are
maintenance procedures and specific manufacturer
also included in the paper. The responsibilities and authorities
recommendations will assure that standby power system will
of operational department is clearly explained.
start and run when it need the most.

Index Terms - Heavy fuel oil, Light fuel oil, Wartsila II. DETAILED DESCRIPTION OF DIESEL POWER
operator interface system. PLANT

I. INTRODUCTION A. Fuel Supply System

Tata Power conceptualized & installed diesel plant between It consists of storage tank, strainers, fuel transfer pump and all
1999 & 2001. The plant went into commercial operation in day fuel tank. The fuel oil is supplied at the plant site by rail or
March 2001.Five units, each consisting of Wartsila make, road. The oil is stored in the storage tank. From the storage
model 18V46 diesel engine coupled to a generator produce tank, oil is pumped to smaller all day tank at daily or short
16.26 MW. The plant also has a fuel oil receiving (by road intervals. From this tank, fuel oil is passed through strainers to
tankers) & fuel oil purification facility. The power generated remove suspended impurities. The clean oil is injected into the
is evacuated at 110 kV through two transmission lines, Tata engine by fuel injection pump.
Line 1 and Tata Line 2 both connected to 220 kV sub-station
at Indal. The islanding scheme, which provided power from Operating principle
Plant to the city of Belgaum during grid disturbances, ceases The fuel oil system is normally operated in a fully automatic
to exist with the Line 2 modification carried out by KPTCL. In mode. HFO (Heavy fuel oil) buffer tanks are automatically
case of a black out the plant can start on its own without the filled by the fuel oil transfer pump system. The HFO is treated
necessity for startup power. Power generated at Alternator in the separator system before being transferred into the HFO
terminal is at 11 kV & is fed to the grid at 110 kV using step fuel oil day tanks. From the day tanks the HFO is fed to the
up transformer. The heavy fuel oil & lube oil are purified by booster unit and from this to each fuel oil unit which supplies
separators using centrifuging technology. The entire plant heat the engine with the fuel at the correct pressure. The LFO is
requirement is met from the steam generated by waste heat stored only in main storage tank, also acting as a day tank.
recovery boilers installed DG exhaust. The Engine & its LFO may be supplied via the booster unit, but can also be fed
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directly from the feeder unit to the fuel oil unit supplying the D. Lubricating System
engine. The system minimizes the wear of rubbing surfaces of the
engine. It comprises of lubricating oil tank, pump, filter and
Operating conditions: oil cooler. The lubrication oil is drawn from the lubricating oil
The HFO & LFO day tanks must be filled with fuel oil of the tank by the pump and is passed through filter to remove
correct quality. impurities .The clean lubrication oil is delivered to the points
which require lubrication. The oil coolers incorporated in the
B. Air Intake System system keep the temperature of the oil low.
This system supplies necessary air to the engine for fuel
combustion. It consists of pipes for the supply of fresh air to Operating condition:
the engine manifold. Filters are provided to remove dust a) The engine crankcase, turbo chargers and governor must
particles from air which may act as abrasive in the engine be filled with lube oil of the correct quality.
cylinder. Diesel engine requires close tolerances to achieve its b) The lube oil cooler must be assembled.
compression ratio, and because most diesel engines are
turbocharged, the air entering the engine must be clean, free of E. Compressed Air System
debris, and as cool as possible. Also, to improve a
turbocharged engines efficiency, the compressed air must be Operating principles:
cooled after being compressed. The air intake system is The compressed air system is normally in continuous
designed to perform these tasks. Air intake systems are usually operation. The air is taken from surrounding and compressed
one of two types, wet or dry. In this plant system used is, a dry into the air receiver. The heat generated is removed in the
filter system. In dry filter system paper, cloth, or a metal radiators installed on the compressor unit.
screen material is used to catch and trap dirt before it enters
the engine. In addition to cleaning the air, the intake system is
Operating conditions:
usually designed to intake fresh air from as far away from the
The air compressor unit must be assembled in operating
engine as practicable, usually just outside of the engines
condition. The air receiver must be assembled, tested and
building or enclosure. This provides the engine with a supply
ready to receive compressed air. The heat generated must be
of air that has not been heated by the engines own waste heat.
removed in the radiators installed on the compressed air.
The reason for ensuring that an engine's air supply is as cool
as possible is that cool air is denser than hot air. This means
F. Charge Air System.
that, per unit volume, cool air has more oxygen than hot air.
Thus, cool air provides more oxygen per cylinder charge than
Operating principles:
less dense, hot air. More oxygen means a more efficient fuel
The charge air system is normally in continuous operation
burn and more power. After being filtered, the air is routed by
when the engine is running. The engine charge air is drawn
the intake system into the engine's intake manifold or air box..
through the external filtration unit and the silencer by the
The intake system also serves to reduce the air flow noise.
engine driven turbo charger. The compressed combustion air
is then transferred into the engine cylinder after heat generated
C. Cooling System
by the compression removed in the charge air cooler and
The heat released by the burning of fuel in the engine cylinder
transferred to the engine jacket water system.
is partially converted into work. The remainder part of the heat
passes through the cylinder wall, piston, rings etc. and may
Operating conditions:
cause damage to system. In order to keep the temperature of
a) The external filtration unit must be in operation.
the engine parts within the safe operating limits, cooling is
b) The intake silencer must be assembled and in operation.
provided. The cooling system consists of a water source, pump
and cooling towers. The pump circulates water through
G. Exhaust System
cylinder and head jacket. The water takes away heat from the
This system leads the engine exhaust gas outside the building
engine and it becomes hot. The hot water is cooled by cooling
and discharges it into atmosphere. A silencer is usually
towers and re circulated for cooling.
incorporated in the system to reduce the noise level. The
exhaust system of a diesel engine performs three functions.
Operating conditions:
First, the exhaust system routes the spent combustion gasses
The engine jacket water system must be filled with treated
away from the engine, where they are diluted by the
coolant of the correct quality. The expansion tanks must be
atmosphere. This keeps the area around the engine habitable.
filled and in operating condition.
Second, the exhaust system confines and routes the gases to
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the turbocharger, if used. Third, the exhaust system allows When the engine start has been selected and confirmed on the
mufflers to be used to reduce the engine noise. WOLS screen, the PLC system will start the engine and then
as engine starts running for approximately ten secs, in auto
Operating condition: mode the PLC system will give a synchronization order to the
The exhaust gas silencer and any other components installed synchronization device.
in the external gas system must be assembled and in operation.
2) Stop sequence.
H. Diesel Engine Normally the engine will be stopped from the operators
Wartsila operator interface system monitor (WOIS). When
Diesel engine is the prime mover, which drives an alternator to engine stop has been selected confirmed on the WOIS screen,
produce electrical energy. In the diesel engine, air is drawn the PLC system will stop the engine according to the preset
into the cylinder and is compressed, during this compression. stop sequence. The generator is first unloaded close to no load
A metered quantity of diesel fuel is then injected into the valve and then breaker open command is given and the engine
cylinder, which ignites spontaneously because of the high is automatically shut down after a 30 sec run without load.
temperature.
The major technical features of generator
Operating principal:
The generator set is normally operated in a fully automatic TABLE I
mode and will start and take up load fully automatically. The TECHNICAL FEATURES OF WARTSILA DG SET
start signal normally given from the Wartsila operator
interface system (WOIS) monitor in the central control room. Machine type AMG 16005512 DSEB
Output 19300 kVA
Voltage 11000 V
Operating conditions: Current 1013A
1) The fuel oil system is activated Engine speed 500 rpm
2) Correct pre heating. Cylinder Bore 460mm
Stroke 580mm
3) Correct pressure. Power factor 0.85
4) Sufficient pre circulation to heat the fuel injection Frequency 50 Hz
pumps. Weight 55000 kg
5) The lube oil system is activated Insulation class F
6) The lube oil system is in operation.
7) The pre lube pump has been in operation for at least There are two types of transformers namely 58 MVA Power
15 mins. Transformers and 2 MVA Aux Transformer. The major
8) The engine air system is activated.. technical features transformers given below.
9) The cooling water air system is activated
10) The pre-heating unit is in operation TABLE II
11) The temperature in the cooling system is correct. 58 MVA POWER TRANSFORMERS
12) The charge air system and exhaust gas system are
activated. Manufacturer Bharat Heavy Electrical
Limited
Serial No 2013455, 56
1) Start sequence. Year of Manufacture 2000
Normally the engine will be started from the operators WOIS Elec Specification No 625789
(Wartsila operator interface system) monitor. Start is possible Diagram Drawing no 14561950445
only if all start conditions are valid and no start blocking is Cooling ONAF
Rating 58 MVA
activated. The conditions are as follows. Insulation Level HV 450 KVP
a) Emergency stops are inactive. Insulation Level LV 75 KVP
b) Engine control alarm is inactive. No load voltage HV 116 KV
c) Generator breaker trip alarm is inactive. No load voltage LV 11 KV
Line Current HV 288.675 A
d) Main breaker trip is in service position.
Line Current LV 3044.210 A
e) Protection relay fault is inactive. Wt of Oil 18200 KG
f) Stop order and starting failure alarm is inactive. Total Wt 92700 KG
g) Auto stop is inactive and electrical pneumatic stop Oil Quantity 20500 Liters
valve is closed.
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TABLE III The plant requires about 2989 m3/day water for its operations.
AUX TRANSFORMER 2 MVA The water requirements will be met from Hidkal reservoir,
Belgaum. In order to minimise the water consumtion, the
Manufacturer EMCO ltd Jalgon engine will be equipped with partial air cooling and water
Serial No 979,980 cooling for injection systems.The treated water meeting the
Year of Manufacture 2000 stipulated standards used for Greenbelt development within
Cooling ONAN plant premises. Excess treated waste water discharged to the
Rating 2 MVA adjacent INDAL industry growth centre for green belt
HV rated voltage 11000 V development.
LV rated voltage 433 V
Line Current HV 105 A
D. Green belt development
Line Current LV 2666.74 A
Wt of Oil 1020 KG
Total Wt 5400 KG An area of about 5 acres is developed under greenbelt. The
Untanking mass 2370 KG green belt design made as per the guideline of Karnataka State
Oil Quantity 1200 Liters Pollution Control Board (KSPCB).

IV OPERATION DEPARTMENT
III. ENVIRONMENTAL MANAGEMENT PLAN
A. Organization chart for operation department
A. Air pollution

Emission from the plant are mainly due to the burning of HOD
heavy fuel oil having sulphur content of 2.0% maximum. As
the ash content in the fuel is less than 0.1%, there will be
negligible emission of particulate matter. The major
pollutants generated from the power plant are sulphur dioxide Shift in charge
and oxides of nitrogen.The generated pollutents are routed to
atmosphere through a single stack of 100m height comprising
of five flues each of 100 m height connected to five DG sets.
The exhaust gases of the diesel engines has high heat energy. Shift engineer
In order to utilise this heat energy in generation of steam for
fuel heating requirements, heat recovery system using waste
heat recovery boilers is considered. Operators

Low NOx combution- Wartsila diesel has developed a low Fig.1 Organization chart
NOx combustion process which reduces the NOx level
without comprising on thermal efficiency. The low NOx
combution is based on the following.
a) A higher combustion air temperature at injection start B. Responsibilities and Authorities
drastically reduces the ignition delay.
b) A retarded injection start and shorter injection period 1) Head of Department
means that combustion takes place at the optimal point
with respect to efficiency. Responsibilities:
1) To ensure systematic and effective operation of the
B. Noise environment plant.
2) To address customer complaints on timely basis and
Proper encasement of noise generating sources done to control lay guidelines for operational activities.
the noise level below 75dB at plant boundary. 3) To optimize resource for competitiveness.
4) Plan for necessary inventory to take care of materials
C. Water environment requirements for plant operation.
5) To comply with all required safety practices.
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6) To initiate and issue indent from the department for 1) To start and stop the equipments as per the
necessary work order / purchase. instruction of control room.
7) Request to purchase department for order 2) To take round in the area periodically for monitoring
amendment. To co-ordinate with other sections. of parameters and observe leakages.
8) To take corrective actions for major critical or 3) To carryout scheduled operational/ maintenance
recurring non-conformities and maintain record for activities as per the instruction.
the same. 4) To log the parameters periodically.
9) Generate and maintain EMS related document for 5) To comply with all required safety practices.
department.
Authority:
Authority: Authorized to stop the equipment during abnormal
1) Approval of group receipt note (GRN). conditions.
2) Authorized to release equipments for maintenance.
3) Authorized to issue material from stores. V. CONCLUSION

2) Shift in charge Preventive maintenance for diesel engine generators plays a


critical role in maximizing reliability, minimizing repairs and
Responsibilities: reducing long term costs. By following generally recognized
1) To handle all the responsibilities related to start and diesel maintenance procedures and specific manufacturer
stop of the plant. recommendations will assure that standby power system will
2) To communicate with KPTCL Bangalore for start and run when it need the most. In order to minimize the
regulating power evacuation to the grid. water consumption, the engine will be equipped with partial
3) To co-ordinate with local 220kv /110 kv substations air cooling and water cooling for injection systems. As all
for load monitoring. engines are V type, model the balancing is easy, resulting in
4) Monitoring of plant parameters and take corrective minimum generation of noise and vibration.
action.
5) Ensure data logging and operational schedules.
REFERENCES
6) To prepare daily generation report and forward to
KPTCL.
[1] Plant operational manual TEC Belgaum,
7) Assist the HOD in maintaining the all relevant
WARTSILA NSD, Corporation.
documents.
[2] Plant maintenance manual TEC Belgaum, WARTSILA
NSD Corporation.
Authority:
[3] Rapid Environmental Impact Assessment report by TATA
1) To send energy export details to KPTCL.
Consulting Engineers (TCE).
2) To raise defect notification through SAP-PM
[4] Power system engineering by M.L.Soni, P.V.Gupta,
module.
U.S.Bhatnagar, A. Chakrabarti.

3) Shift engineer
BIOGRAPHY
Responsibility:
Priyanka Mankale, was born in Karnataka, India on 06 April 1987.
a) To assist shift incharge activities related to start and
She obtained B.E (Electrical and Electronics) from Vishveswaraya
stop of plant and prepare various reports. Technological University, Belgaum, Karnataka, India. She is
b) To attend various schedules related to operational currently persuing M.Tech Degree in Power and Energy Systems in
requirement. Electrical and Electronics Engineering, Basaveshwar Engineering
c) Data logging for various parameters. College, Bagalkot, India. Her areas of interest include Power
d) To attend electrical jobs and comply with all required Systems, Power Electronics and Drives.
safety practices.
e) To carryout jobs as per operation schedule. Sunita S. Tambakad, was born in Bijapur, Karnataka, India on 3
August 1982. She obtained B.E (Electrical and Electronics) from
4) Field Operator Visveswaraih Technological University, Belgaum, Karnataka India in
2005 and M.Tech (Power and Energy System) from Basaveshwar
Engineering College, Bagalkot, Karnataka, India in 2009.
Responsibility:
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Presently she is working as faculty in the Department of Electrical &


Electronics Engineering at Basaveshwar Engineering College,
Bagalkot, India.

Dr. Suresh. H. Jangamshetti: (S'88, M'90, SM'97) was born in


Bijapur, Karnataka, India on May 28, 1963. He obtained his B.E
(Electrical) degree from Karnataka University Dharwad in 1985 and
M.Tech. (Power Systems) & Ph.D (Wind Energy Systems) from IIT
Kharagpur in 1989 & 2000 respectively.

His areas of interest include Wind-Solar Energy Systems, Energy


Conservation, Computer Applications to Power System and FACTS
He won the "Outstanding IEEE Student Branch Counsellor" award
for the year 1996(R10) and 2010 (IEEE Bangalore Section) at
Basaveshwar Engineering College, Bagalkot, Karnataka, India. He
was Fulbright-Nehru Visiting Lecture Fellow at Michigan
Technological University, Houghton MI USA during Fall 2011. He is
working as Professor in the department of E&E at Basaveshwar
Engineering College, Bagalkot.

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