STATIONARY POWER
Project Guide
for Diesel Power Plants
Project Guide
for Diesel Power Plants
Stationary Plants
Status 07.2004
.
Titelseite P.fm
Contents
2 Engine................................................................................ 2 - 1
2.1 Data concerning all engines ............................................................................. 2-3
2.1.1 Historical development of MAN B&W Diesel engines ......................................... 2 - 3
2.1.2 Programme for works test of four-stroke engines............................................... 2 - 9
2.1.3 Earthing measures on Diesel engines and bearing insulation on generators.... 2 - 10
2.1.4 Engine Running-in ............................................................................................. 2 - 12
2.1.5 Acceleration times ............................................................................................. 2 - 15
2.1.6 Standard reference conditions .......................................................................... 2 - 17
2.1.7 Load application ................................................................................................ 2 - 18
2.1.8 Adjustment of output and power....................................................................... 2 - 23
2.1.9 Exhaust gas emissions ...................................................................................... 2 - 28
2.1.10 Generator plants in isolated operation .............................................................. 2 - 30
2.1.11 Turbo charger and charge air cooler ................................................................. 2 - 32
2.1.12 Jet Assist ........................................................................................................... 2 - 33
2.1.13 Condensate amount .......................................................................................... 2 - 35
3 Quality requirements........................................................ 3 - 1
3.1 Quality of lube oil for operation on gas oil and Diesel oil (MGO/MDO) ........ 3-3
4 Genset ............................................................................... 4 - 1
4.1 Genset for engine V48/60 .................................................................................. 4-3
6.1 Engine-related modules and components - data concerning all engines ... 6-3
6.1.1 Selection of economic serial products and procurement of accessories (electric mo-
tors, pumps, strainer and filter, control valves, cooler/ heat exchanger) ............ 6 - 3
6.1.1.1 Electric motors ................................................................................... 6 - 3
6.1.1.2 Pumps ................................................................................................ 6 - 4
6.1.1.3 Strainer ............................................................................................ 6 - 15
9.2 Exhaust gas treatment system - description for all plants ............................ 9-4
9.2.1 Selective catalytic reduction system (DeNOx)..................................................... 9 - 4
9.2.2 Desulphurisation system (DeSOx) ....................................................................... 9 - 6
Buch PowerPlant 48-60 externIVZ.fm
10.2 Exhaust gas treatment modules and components -photographs of existing power
plants 10 - 9
10.2.1 Desulphurisation (DeSOx) with NaOH- scrubber .............................................. 10 - 9
10.2.2 Desulphurisation (DeSOx) with limestone- scrubber....................................... 10 - 10
10.2.3 ESP for V48/60 ................................................................................................ 10 - 13
11.4 Concept layout for MAN B&W Diesel standard scope ............................... 11 - 31
13.2 Plant service and protection systems- drawings for all plants ................. 13 - 11
13.2.1 Schematic diagram treatment of contaminated process waters .................... 13 - 11
13.2.2 Components .................................................................................................... 13 - 13
13.2.2.1 Leakage oil/sludge module ............................................................ 13 - 13
13.2.2.2 Photograph of installed leakage oil/sludge module ....................... 13 - 15
Buch PowerPlant 48-60 externIVZ.fm
13.3 Plant service and protection systems- drawing for 55 MW plant ........ 13 - 21
13.3.1 Work air system .............................................................................................. 13 - 22
13.3.2 Sludge-, leakage-, HFO treatment- and discharge system.......................... 13 - 26
13.3.3 Heavy- fuel oil separator- module ................................................................... 13 - 29
14 Buildings ......................................................................... 14 - 1
14.1 Descriptions for engines V32/40 and V48/60 ................................................ 14 - 3
14.1.1 Power House ..................................................................................................... 14 - 3
14.1.2 Power House Ventilation system ..................................................................... 14 - 30
14.1.3 Power House crane ......................................................................................... 14 - 39
14.1.3.1 Sole plate 48/60 ............................................................................. 14 - 41
14.1.4 Pump House, fuel treatment............................................................................ 14 - 47
14.1.4.1 Ventilation of the separator room .................................................. 14 - 48
14.1.5 Unloading and weighting station ..................................................................... 14 - 51
14.1.6 Work shop and stores ..................................................................................... 14 - 53
15 Project engineering........................................................ 15 - 1
15.1 Minimum data for quotation of MAN B&W Diesel stationary power plant . 15 - 3
16 Appendix ......................................................................... 16 - 1
Buch PowerPlant 48-60 externIVZ.fm
16.6 Flow rate and velocity diagram for liquids, gases and vapours ................ 16 - 45
16.7 Calculation of the system resistance and adjustment of the centrifugal pump to
the service point 16 - 47
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
0101-0101PA.fm
Comprising 3 x engine 18V 48/60 When receiving a MAN B&W Diesel quotation,
you will recognise the PDS-Numbers.
Power plant 105MW
Comprising 6 x engine 18V 48/60 Engine versions
According to your needs, the Project Guide de- Several MAN B&W Diesel engines are available
scribes either as L-engines as well as V-engines. In the Project
Guide, please note that the texts, tables and fig-
all above mentioned engines and power ures are marked as follows:
plants, or
Letter "L" or "V" before the engine type
one engine or plant of your interest.
The information is valid for the stated engine
Projedat version only.
0102-0101PA.fm
25MW power plant Three dimensional view generated from plant design
1. Power house
2. Exhaust gas boiler plant
3. DeSOx plant
4. Radiator cooler plant
5. Tank farm
6. Pump house
7. Workshop store
0103-0101PA.fm
Figure 1-3 Side view of power house - example for 25MW power plant
25MW power plant Typical layout drawing (consisting of figure 1-4 to 1-5)
0103-0101PA.fm
Figure 1-4 Cross section and view from above - example for 25MW power plant
25MW power plant Typical layout drawing (consisting of figure 1-4 to 1-5)
0103-0101PA.fm
Figure 1-5 Table for plant equipment and weights - example for 25MW power plant
55MW power plant Three dimensional view generated from plant design
1. Power house
2. Exhaust gas duct
3. Air intake
4. Chimney
5. Radiator cooler plant
Figure 1-7 Power house and radiator cooler plant - example for 55MW power plant
0103-0101PA.fm
55MW power plant Typical layout drawing (consisting of figure 1-11 to 1-14)
0103-0101PA.fm
Figure 1-11 Power house, sectional view - example for 55MW power plant
55MW power plant Typical layout drawing (consisting of figure 1-11 to 1-14)
0103-0101PA.fm
55MW power plant Typical layout drawing (consisting of figure 1-11 to 1-14)
0103-0101PA.fm
Figure 1-13 Power house, topview - example for 55MW power plant level above 0,00, level above + 6,50, level above
+10,50.
55MW power plant Typical layout drawing (consisting of figure 1-11 to 1-14)
Figure 1-14 Table for plant equipment and weights - example for 55MW power plant
0103-0101PA.fm
105MW power plant Three dimensional view generated from plant design
1) Power house
2) Exhaust gas duct
3) Air intake
4) chimney
5) Radiator cooler
6) Tank farm
7) Pump house
Figure 1-16 Power plant with 3 x 55MW (165 MW)
0103-0101PA.fm
105MW power house Typical layout drawing (consisting of figure 1-18 to 1-21)
0103-0101PA.fm
Figure 1-18 Power house cross section - example for 105MW power plant
105MW power plant Typical layout drawing (consisting of figure 1-18 to 1-21)
0103-0101PA.fm
Figure 1-19 Longitudinal section of power house - example for 105MW power plant
105MW power plant Typical layout drawing (consisting of figure 1-18 to 1-21)
0103-0101PA.fm
Figure 1-20 Power house - topview example for 105MW power plant, above level 0,00, above level + 6,5, above level
+ 20,50
105MW power plant Typical layout drawing (consisting of figure 1-18 to 1-21)
Figure 1-21 Table for plant equipment and weights - example for 105MW power plant
0103-0101PA.fm
0104-0101PA.fm
Figure 2-1 Development of mean effective pressure (left) and mean piston speed (right)
0201-0101PA.fm
Figure 2-6 HFO operation with exhaust gas treatment and heat recovery
0201-0101PA.fm
1 100 60 25
Figure 2-7 Operating points to be considered during the acceptance test run
Remarks
Further load points can only be demonstrated
during the acceptance test run (30 minutes
each), if this is part of the contract.
After the acceptance test run, the compo-
nents will be inspected, as far as this is pos-
sible without dismantling them.
Components will only be removed on cus-
tomers order.
0201-0201PA.fm
General
The use of electrical equipment on Diesel en-
gines requires precautions to be taken for pro-
tection against shock current and for
equipotential bonding. These not only serve as
shock protection but also for functional protec-
tion of electric and electronic devices (EMC pro-
tection, device protection in case of welding,
etc.).
In the case of engines driving generators, the Idling at high speed over an extended period is
engine speed is, within the specified period, at to be avoided, wherever possible.
first increased up to the normal speed before
load is applied. During the entire running-in pe- Running-in after low-load operation
riod, the engine output is to remain within the Continuous operation in the low-load range may
output range that has been marked in Figure 2- result in heavy internal contamination of the en-
9, Page 2-14 and Figure 2-10, Page 2-14, resp. gine. Combustion residues from the fuel and lu-
Critical speed ranges are to be avoided. bricating oil may deposit on the top-land ring of
the piston, in the ring grooves and possibly also
Running-in during commissioning at site in the inlet ducts. Besides, the charge air and ex-
Four-stroke engines are, with a few exceptions, haust piping, the charge air cooler, the turbo-
always subject to a test run in the manufactur- charger and the exhaust gas boiler may become
ers works, so that the engine has been run in, as oily.
a rule. Nevertheless, repeated running is re- As also the piston rings will have adapted them-
quired after assembly at the final place of instal- selves to the cylinder liner according to the
lation if pistons or bearings were removed for loads they have been subjected to, accelerating
inspection after the test run or if the engine was the engine too quickly will result in increased
partly or completely disassembled for transpor- wear and possibly cause other types of engine
tation. damage (piston ring blow-by, piston seizure).
After prolonged low-load operation ( 500 oper-
Running-in after installation of new running gear
ation hours), the engine should therefore be run
components
in again, starting from the output level, at which
0201-0401PA.fm
In case cylinder liners, pistons and/or piston it has been operated, in accordance with Figure
rings are replaced on the occasion of overhaul 2-9, Page 2-14 and Figure 2-10, Page 2-14.
work, the engine has to be run in again. Run-
Figure 2-9 Standard running-in program for engine 32/40 (constant speed)
A Engine speed nM D Running-in period [h]
B Engine output (specified range) E Engine speed and output [%]
0201-0401PA.fm
Figure 2-10 Standard running-in program for engine 48/60 (constant speed)
A Engine speed nM D Running-in period [h]
B Engine output (specified range) E Engine speed and output [%]
Figure 2-11 Running-up and loading times, lube oil 20C, engine cooling water 20C
Figure 2-12 Runningup and loading times, lube oil 40C, engine cooling water 60C
General definition of Diesel engine rating ISO reference conditions No de-rating required in case of
(according to ISO 15550: 2002; ISO 3046-1 : 2002)
Cooling water temperature upstream of charge air 298 K (25C) 315 K (42C)
cooler Tcr (tcr)
Available outputs/ related Nominal output according Fuel stop power Other conditions
reference conditions to Project Guide
% % -
Notes:
(1) Blocking of the output is made at 110% of
the maximum continuous output.
Output greater than the max. continuous output at site
may only be run for a short time for the governing pur-
poses.
Please see also sheet Power adjustment for ambient
conditions at site for stationary power plants on
page 25..
(2) Consultation with MAN B&W Diesel AG is required
(3) Permissible total running time according to DIN6280
1000h/a.
0201-0502PA.fm
Load application from 0% to 100% rating Depending on the mean effective pressure of the
(ISO 8528-5 requirements) engines a load application from 0 to 100% re-
sults in the number of load steps an their per-
For applications in the range from 0% to 100%
centages given in the table below.
of the site rating, the requirements according to
Section 9 and Figure 6 of ISO 8528-5: 1993 ap-
ply. Please also refer the figure below.
Engine bmep 1st step 2nd step 3rd step 4th step
bar % % % %
Table 2-1 Mean effective pressures and application loads according to ISO 8528-5
The percentage of the load steps referring to a bmep of 24.8bar in the diagram.
0201-0601PA.fm
Figure 2-14 Load application depending on the current load according to ISO 8528-5
Figure 2-15 Load application depending on the current load allowed by MAN B&W Diesel AG
Recommended load reduction / stopping the high for all load conditions which, however is of
engine particular importance during operation on heavy
fuel oil.
Unloading the engine
Better conditions
In principle, there are no regulations with re-
gard to unloading the engine. However, a Engines are genuinely better equipped for low-
minimum of 1 min. is recommended for un- load operation
loading the engine from 100% PNominal to ap-
if they have a two-stage charge-air cooler, the
prox. 25% PNominal.
second stage of which can be switched off in
order to improve the operating data or
Engine stop
if they have a two-stage charge-air cooler
As from 25% PNominal, further engine unload- and switch-over from HT to LT has been pro-
ing is possible, without interruption, and af- vided for, permitting the admission of HT wa-
terwards the engine can be stopped. ter to the LT stage.
Figure 2-16 Time limits for part-load operation on heavy fuel oil (on the left), duration of relieving operation(on the right)
Explanations Example
Figure on the left: Line a:
Time limits for part-load operation on heavy At 10% of full-load output, HFO operation is
fuel oil permissible for maximum 19 hours, then switch
over to Diesel fuel oil, or
Figure on the right:
Line b:
Necessary operation time at > 70% of full-
load output after part-load operation on Operate the engine for approx. 1.2 hours at not
heavy fuel oil. Acceleration time from present less than 70% of full-load output to burn away
output to 70% of full-load output not less the deposits that have formed. Subsequently,
0201-0601PA.fm
Power adjustment for ambient conditions at px Ambient total air pressure at site [kPa]
site for stationary power plants Pr Nominal output acc. to table of ratings [kW]
Px Output at site [kW]
The nominal output of Diesel engines for station-
tcx Charge air coolant temperature at site [C]
ary power plants is defined for the standard ref-
tEx Correction temperature for exhaust pressure [C]
erence conditions given in Table 2-2, Page 2-25.
tx Ambient air temperature at site [C]
Also see "Outputs, speeds and designations"of Tcra Substitute reference for charge air coolant
the respective engine in Chapter 2 "Engine", thermodynamic temperature = 315 [K]
Page 2-1. Tra Substitute reference for ambient air thermodynamic
temperature = 308 [K]
Reference Conditions:
ISO 3046-1: 2002; ISO 15550: 2002 Output can be overloaded up to 10% for a short time for
governing purposes (ISO 8528-1:1993).
Air temperature Tr K / C 298/ 25
pEx Exhaust gas overpressure after turbine [kPa] bustion engines as defined in ISO 3046-1.
pra Substitute reference for total barometric pressure
= 95.5 [kPa]
0201-0702PA.fm
Composition of exhaust gas of medium combustion process. Only some of these are to
speed four-stroke Diesel engines be considered as harmful substances.
The exhaust gas of a medium speed four-stroke The table below show the typical composition of
Diesel engine is composed of numerous of con- the exhaust gas of an MAN B&W Diesel four-
stituents. These are derived from either the stroke Diesel engine at full load and without any
combustion air and fuel oil and lube oil used, or exhaust gas treatment devices
they are reaction products, formed during the
Main exhaust gas constituents approx. [% by volume] approx. [g/kWh]
Nitrogen N2 74.0 - 76.0 5020 - 5160
Oxygen O2 11.6 - 12.6 900 - 980
Carbon dioxide CO2 5.2 - 5.8 560 - 620
Steam H2O 5.9 - 8.6 260 - 370
Inert gases Ar, Ne, He... 0.9 75
Total > 99.75 7000
8) Heavy fuel oil RM-B grade with an ash content of the fuel oil of 0.1 % and an ash content of the lube oil of 4.0 %
Hydrocarbons HC
The hydrocarbons (HC) contained in the exhaust
gas are composed of a multitude of various or-
ganic compounds as a result of incomplete
combustion.
Due to the efficient combustion process, the HC
content of exhaust gas of MAN B&W four-stroke
Diesel engines is at a very low level.
Isolated operation range and, in case one unit fails, that unimpor-
tant users can be switched off by the Power
A power plant, as standalone power supplier for
Management System to avoid failure of the sys-
a consumer net, operates in isolated operation.
tem.
Plant layout
Plant layout without Power Management
When planning such a plant, the possible failure System
of one generating unit must to be allowed for in
In the case of plants in isolated operation with-
order to avoid overloading the remaining en-
out Power Management System, the generating
gines, and thus risking a black-out. For maxi-
unit output should be adjusted in such a way
mum allowed load application see Chapter 2.1.7
that, in case one unit fails, the sudden loss in
"Load application", Page 2-18.
output can be compensated for by the other en-
gines in operation.
Plant layout with Power Management System
(PMS) Taking into account the permissible load appli-
cation (see Chapter 2.1.7 "Load application",
For power stations with several generating units,
Page 2-18), the recommended utilisation de-
which are working in isolated operation, we ad-
pending on the number of generating units run-
vise equipping with a Power Management Sys-
ning can be stated as given in Table 2-4, Page
tem.
2-30
This is the only way to ensure that the generating
units can be operated in the maximum output
Application No. of manoeuvres per hour / No. of manoeuvres, which take place
Average duration in rapid succession, if necessary
Table 2-5 Guiding values for the number of Jet Assist manoeuvres dependent on application
0201-1002PA.fm
0201-1002PA.fm
Engine V 48/60
Engine ratings
Engine 48/60
Speeds/main data
Unit 50 Hz 60 Hz
Cylinder rating kW (PS) 1,050 (1,430) 1,050 (1,430)
Rated speed rpm 500 514
Mean piston speed m/s 10.0 10.3
Mean effective pressure bar 23.2 22.6
Number of pole pairs - 6 7
1)
Highest engine operating rpm 525 525
speed
1)
This concession may possibly be restricted. See Chapter 2.1.8 "Adjustment of output and power", Page 2-23.
0203-0102PD.fm
Engine V 48/60
Engine designation and design parameters
Cylinder bore 48
cm
Piston stroke 60
Vee angle 50
Engine V 48/60
Dimensions and weight
0203-0201PD.fm
Engine V 48/60
Cross section
Figure 2-22 Cross section, view on counter coupling side - engine V 48/60
0203-0202PD.fm
0203-0202PD.fm
Engine V 48/60
Output 1050 kW/cyl., speed = 500/514 rpm
Engine noise
Engine V 48/60
Output.
Intake noise
0203-0601PD.fm
Engine V 48/60
Output 1050 kW/cyl., speed = 500/514 rpm
Exhaust gas noise
Engine V 48/60
1050 kW/cyl.; 500/514 rpm
Coolers
1)
Tolerance: +10% for rating coolers, -15% for heat recovery
2) Including separator heat (30kJ/kWh)
3) Without back washing oil required for filter, reserve for control valve and the tolerances of the pump delivery capacities.
0203-0901PD.fm
Table shows guide values only. Please contact MAN B&W Diesel to have exact values calculated.
Engine V 48/60
1050 kW/cyl.; 500/514 rpm
Air and exhaust gas data
Air temperature 25
C
Cooling water temperature before charge air cooler 32
(LT stage)
Relative humidity % 30
Air data
Engine 48/60
Water and oil volume of engine, flow resistances, operating pressures
1)
All pressures overpressures
Engine 48/60
Maintenance
Component Spot checks Spot checks Time between overhauls Time between overhauls
5,000 - 6,000 h 10,000 - 12,000 h 15,000 - 20,000 h 30,000 - 40,000 h
The intervals are guidelines. Correct operation and maintenance must be ensured.
0203-1001PD.fm
Engine 48/60
Spare parts
0203-1002PD.fm
Engine 48/60
Spare parts
0203-1002PD.fm
Engine V 48/60
Major spare parts
0203-1003PD.fm
Figure 2-27 Explanation of acting forces and moments on the turbocharger exhaust- outlet
11 Nozzle ring
12 Gas-admission casing
13 Turbine blades
technologies, introduced into the series by MAN discharge connections. The compressor cas-
B&W Diesel with use of the latest developmental ing houses the diffuser, which allows for op-
Function
The exhaust gas of the engine flows through the
gas-admission casing and the nozzle ring, and
runs axially onto the turbine wheel. The exhaust
gas drives the turbine wheel; in this process, the
energy contained in the exhaust gas is trans-
formed into mechanical rotation energy at the
turbine wheel. As the turbine wheel and the
compressor wheel are seated on the same shaft,
the compressor wheel is driven at the same
time. The exhaust gas exits the turbocharger
through the gas-outlet diffuser and the gas out-
let casing.
The compressor wheel draws in fresh air
through the silencer or the intake casing and the
insert. The fresh air is compressed in the com-
pressor wheel, diffuser and compressor casing.
The compressed fresh air is forced into the cyl-
inders of the engine via charge air cooler and
charge air pipe.
The running equipment of the turbocharger is
led radially by two bearing bushes, which are sit-
uated in the bearing casing between turbine
wheel and compressor wheel. The thrust bear-
ing positioned on the compressor side not only
handles the axial guidance, but also transfers
the thrust in axial direction. A bearing body
holds the bearing seat and at the same time is
used as insulation against the hot exhaust-gas
side of the turbocharger.
0203-1101PD.fm
Functional description
Lube Oil Circuit:
The lubrication and cooling of the high-stressed
bearing bushes in the turbocharger takes place
by means of a lube oil system, which is integrat-
ed mainly in the bearing casing.
The lubricating oil is supplied from the lube oil
system of the engine to the lube oil system of the
turbocharger via a supply pipe (1). A pressure
reduction valve (2.1) (four-stroke engine) adjusts
the required lube oil pressure. The lube oil pres-
sure is controlled behind the non-return valve (4)
by means of a pressure monitor (5) and a ma-
nometer (6).
The lubrication oil flows through the non-return
valve (4) into the turbocharger casing, from
where it reaches the thrust bearing (8) and the
bearing bushes (9) via passages in the bearing
casing (7) and the bearing body. The lubricating
oil flows to the gap between bearing and shaft
as well as to the face-sided lubrication point of
the thrust bearing via bores in the bearing bush-
es. The lubricating oil leaves the gap between
the bearing and the shaft and is splashed
against the wall of the bearing casing by the ro-
tation of the shaft. The lubricating oil exits the
bearing casing through the drain pipe (10) and
flows back into the lube oil system of the engine
(11).
0203-1101PD.fm
Functional description flows out of the compressor casing (1) into a ring
duct (2) in the bearing casing. From there, the air
The sealing air prevents hot exhaust gas from
is led into the sealing air pipe (4), whereby an or-
entering the bearing casing and the lubricating
ifice (3) reduces the pressure to the required
oil from seeping into the turbine (oil coke). Addi-
sealing air pressure. The air is led to a ring duct
tionally, undesirable axial thrust on the bearing
(5) on the turbine side of the bearing casing.
bushes is reduced.
There, the sealing air emerges between shaft
0203-1101PD.fm
The sealing air system is fully integrated in the and turbine labyrinth.
bearing casing (11). A part of the air compressed
by the compressor wheel (C) is diverted and
The granulate container is filled with cleaning turbine wheel, thus removing deposits and con-
granulates and shut tight. The stop cock (A) in tamination. The exhaust gas flow carries the
Operating conditions
The granulate container (3) must be fastened
at a suitable location. It may not be not be po-
sitioned lower than 1 m below the connection
flange (5).
The pipe (4) may not be longer than 6 m and
must be supported against vibrations. Ensure
unobstructed flow.
Maximum operating temperature of the stop
cock (B) (exhaust gas): 150C.
The connection flange (5) can be attached ei-
ther at the adapter (6) of the exhaust gas pipe
or directly at the gas-admission casing (7).
0203-1101PD.fm
Functional Description
The wet cleaning of the compressor is per-
formed during operation at full load.
The water tank (5) is filled with fresh water and
tightly closed with the screwed connection. If
the key-button valve (3) is opened, compressed
air flows from the charge air pipe (1) into the wa-
ter tank and presses the water out of the tank
through the hose (6) to the injection pipe (7). The
injection pipe sprays the water in the compres-
sor casing (8) in front of the compressor wheel.
The water droplets bounce against the com-
pressor wheel, where they wear off the contam-
0203-1101PD.fm
ination.
0203-1101PD.fm
3.1 Quality of lube oil for operation on gas oil and Diesel oil
(MGO/MDO)
PDS: 10, 30, 40, 90
The specific power output offered by todays as specified in Table 3-1, Page 3-3, particularly
Diesel engines and the use of fuels which more as concerns its aging stability.
and more often approach the limit in quality in-
crease the requirements placed on the lube oil Doped lube oils (HD-oils)
and make it imperative that the lube oil is chosen
The base oil with which additives have been
carefully. Doped lube oils (HD oils) have proven
mixed (doped lube oil) must demonstrate the fol-
to be suitable for lubricating the running gear,
lowing characteristics:
the cylinder, the turbocharger and for the cool-
ing of the pistons. Doped lube oils contain addi-
tives which, amongst other things, provide them Additives
with sludge carrying, cleaning and neutralization The additives must be dissolved in the oil and
capabilities. must be of such a composition that an absolute
Only lube oils, which have been released by minimum of ash remains as residue after com-
MAN B&W Diesel, are to be used. These are list- bustion. The ash must be soft. If this prerequisite
ed in Table 3-3, Page 3-5. is not complied with, increased deposits are to
be expected in the combustion chamber, espe-
cially at the outlet valves and in the inlet housing
Specifications
of the turbochargers. Hard additive ash pro-
motes pitting on the valves seats, as well as
Base oil
burnt-out valves and increased mechanical
The base oil (doped lube oil = basic oil + addi- wear.
tives) must be a narrow distillation cut and must
Additives must not facilitate clogging of the filter
be refined in accordance with modern proce-
elements, neither in their active nor in their ex-
dures. Bright stocks, if contained, must neither
hausted state.
adversely affect the thermal nor the oxidation
stability. The base oil must meet the limit values
TEBOIL Ward S 10 T
0302-0101AA.fm
3.2 Quality of lube oil for heavy fuel oil operation (HFO)
PDS: 10, 30, 40, 90
The specific power output offered by todays ther adversely affect the thermal nor the
Diesel engines and the use of fuels which more oxidation stability.
and more often approach the acceptable limit in
The base oil must meet the limit values given in
quality increase the requirements placed on the
Table 3-4, Page 3-7, particularly as concerns its
lube oil and make it imperative that the lube oil
aging stability.
is chosen carefully. Medium-alkaline lube oils
have proven to be suitable for lubricating the
Medium-alkaline lube oil
running gear, the cylinders, the turbocharger
and, if applicable, for the cooling of the pistons. The base oil with which additives have been
Medium-alkaline oils contain additives which, mixed must demonstrate the following charac-
amongst other things, provided them with a teristics.
higher neutralising capacity than doped (HD) en-
gine oils have. Additives
No international specifications exist for medium- The additives must be dissolved in the oil and
alkaline lube oils. An adequately long trial oper- must be of such a composition that an absolute
ation in compliance with the manufacturers in- minimum of ash remains as residue after com-
structions is therefore necessary. bustion, even though the engine were run on
Only lube oils, which have been released by distillate fuel temporarily. The ash must be soft.
MAN B&W Diesel, are to be used. These are list- If this prerequisite is not complied with, in-
ed in Table 3-7, Page 3-10. creased deposits are to be expected in the com-
bustion space, especially at the exhaust valves
and in the inlet housing of the turbochargers.
Requirements
Hard additive ash promotes pitting on the valve
seats, as well as burnt-out valves and increased
Base oil
mechanical wear in the cylinder space.
The base oil (medium-alkaline lube oil = base oil
Additives must not facilitate clogging of the filter
+ additives) must be a narrow distillation cut and
elements, neither in their active nor in their ex-
must be refined in accordance with modern pro-
hausted state.
cedures. Bright stocks, if contained, must nei-
Further conditions
The lube oil must not form a stable emulsion
with water. Less than 40ml emulsion are accept-
able in the ASTM-D1410 test after one hour. The
foaming behaviour (ASTM-D892) must meet the
following conditions: after 10 minutes <20ml.
The lube oil must not contain agents to improve
viscosity index. Fresh oil must not contain any
water or other contamination.
0302-0102AA.fm
Marine Diesel Oil (MDO) of poor quality (ISO-F-DMC) or heavy fuel oil with sulphur content of
~20 - 25
(0.5% by weight)
~30 For 32/40, 40/54, 48/60 and 58/64 engines only if sulphur concentration <1.5%.
For 32/40, 40/54, 48/60 and 58/64 engines generally, provided the sulphur concentration is
~40
>1,5%.
For 32/40, 40/54, 48/60 and 58/64 engines if BN 40 is inadequate in terms of time between
~50
renewal of oil charge (high sulphur content of the fuel, very low oil consumption).
Speed governor more than willing to provide you with further in-
formation.
In case of mechanic-hydraulic governors with
separate oil sump, multi grade oil 5W-40 is pref-
erably used. If this oil is not available as refill, an Examinations
oil 15W-40 can be used for once. In this context We carry out the investigations on lube oil in our
it is not important, if multi grade oils based on laboratories for our customers who need only
synthetic or mineral oil are used. According to pay the self-costs (net-costs). A representative
the mineral oil companies they can be mixed in sample of about 1litre is required for the exami-
all cases. nation.
The oil quality specified by the manufacturer is
to be used for the remaining equipment fitted to
the engine.
Lube-oil additives
We advise against subsequently adding addi-
tives to the lube oil, or mixing the different
makes (brands) of the lube oil, as the perform-
ance of the carefully matched package of addi-
tives which is suiting itself and adapted to the
base oil, may be upset. Also, the lube oil compa-
ny (oil supplier) is no longer responsible for the
oil.
20 - 25 30 40
ADNOC Marine Engine Oil X424 Marine Engine Oil X430 Marine Engine Oil X440
CASTROL TLX 204/TLX Plus 204 TLX 304/TLX Plus 304 TLX 404/TLX Plus 404
IRVING Marine MTX 2040 Marine MXD 3040 Marine MXD 4040
Table 3-7 Lubricating oils, which have been released for the use in MAN B&W Diesel four-stroke engines running on
heavy fuel oil
We do not assume any reponsibility for difficulties that might be caused by these oils
0302-0102AA.fm
0.179mmol/litre
2) 1 mg/l 1 ppm hardness) must be mixed with distillate or be
softened. A rehardening of excessively soft wa-
ter is only necessary to suppress foaming if an Protecting films can be produced by treating the
emulsifiable anti-corrosion oil is used. cooling water with a chemical anti-corrosion
agent or emulsifiable anti-corrosion oil.
Damage in the cooling water system Emulsifiable anti-corrosion oils fall more and
more out of use since, on the one hand, their use
Corrosion is heavily restricted by environmental protection
Corrosion is an electro-chemical process which legislation and, on the other hand, the suppliers
can largely be avoided if the correct water qual- have, for these and other reasons, commenced
ity is selected and the water in the engine cool- to take these products out of the market.
ing system is treated carefully.
Treatment before operating the engine for the
Flow cavitation first time
Flow cavitation may occur in regions of high flow Treatment with an anti-corrosion agent should
velocity and turbulence. If the evaporation pres- be done before the engine is operated for the
sure is fallen below, steam bubbles will form first time so as to prevent irreparable initial dam-
which then collapse in regions of high pressure, age.
thus producing material destruction in closely Attention!
limited regions.
It is not allowed to operate the engine without
Erosion cooling water treatment.
Corrosion fatigue is a damage caused by simul- A cooling water additive can be approved for
taneous dynamic and corrosive stresses. It may use if it has been tested according to the latest
induce crack formation and fast crack propaga- rules of the Forschungsvereinigung Verbren-
tion in water-cooled, mechanically stressed nungskraftmaschinen (FVV), Testing the suita-
components if the cooling water is not treated bility of coolant additives for cooling liquids of
correctly. internal combustion engines (FVV publication R
443/1986). The test report is to be presented if
Treatment of the engine cooling water required. The necessary testing is carried out by
Staatliche Materialprfanstalt, Department
The purpose of engine cooling water treatment Oberflchentechnik, Grafenstrae 2, 64283
is to produce a coherent protective film on the Darmstadt on request.
walls of the cooling spaces by the use of anti-
corrosion agents so as to prevent the above- To be used only in closed circuits
mentioned damage. A significant prerequisite
for the anti-corrosion agent to develop its full ef- Additives can only be used in closed circuits
fectively is that the untreated water which is where no appreciable consumption occurs ex-
used satisfies the demands mentioned under cept leakage and evaporation losses.
"Requirements", Page 3-11.
0302-0201AA.fm
If chemical additives or anti-freeze agents are Anti-corrosion agents are a contaminating load
used, the water should be changed after three for the water in general. Cooling water must
years at the latest. therefore not be disposed off by pouring it into
the sewage system without prior consultation
If excessive concentrations of solids (rust) are
with the competent local authorities. The re-
found, the water charge has to be renewed
spective legal regulations have to be observed.
completely, and the entire system has to be
thoroughly cleaned.
The causes of deposits in the cooling system
may be leakages entering the cooling water,
breaking of the emulsion, corrosion in the sys-
tem and calcareous deposits due to excessive
water hardness. An increase in the chloride ion
content generally indicates sea water leakage.
The specified maximum of 50mg/kg of chloride
ions must not be exceeded, since otherwise the
danger of corrosion will increase. Exhaust gas
leakage into the cooling water may account for
a sudden drop in the pH value or an increase of
the sulphate content.
Water losses are to be made up for by adding
untreated water which meets the quality de-
mands according to "Requirements", Page
3-11. The concentration of the anti-corrosion
agent has subsequently to be checked and cor-
rected if necessary.
Checks of the cooling water are especially nec-
essary whenever repair and servicing work has
been done in connection with which the cooling
water was drained.
Protective measures
Anti-corrosion agents contain chemical com-
pounds which may cause health injuries if
wrongly handled. The indications in the safety
data sheets of the manufacturers are to be ob-
served.
Prolonged, direct contact with the skin should
be avoided. Thoroughly wash your hands after
use. Also, if a larger amount has been splashed
onto the clothing and / or wetted it, the clothing
should be changed and washed before being
worn again.
If chemicals have splashed into the eyes, imme-
0302-0201AA.fm
Paros, France
Product
Manufacturer
(Designation)
BP Marine
Breakspear Way Diatsol M
Hemel Hempstead Fedaro M
Herts HP2 4UL, UK
Castrol Int.
Pipers Way Solvex WT 3
Swindon SN3 1RE, UK
DEA Minerall AG
berseering 40 Targon D
22297 Hamburg, Germany
Deutsche Shell AG
berseering 35 Oil 9156
22284 Hamburg, Germany
Product Minimum
Manufacturer
(Designation) concentration
BASF Glysantin G 48
Carl-Bosch-Str. Glysantin 9313
67063 Ludwigshafen, Rhein, Germany Glysantin G 05
Castrol Int.
Pipers Way Antifreeze NF,SF
Swindon SN3 1RE, UK
BP, Britannic Tower, Moor Lane,
Antifrost X 2270A
London EC2Y 9B, UK
DEA Minerall AG
berseering 40 Khlerfrostschutz 35 %
22297 Hamburg, Germany
Deutsche Shell AG
berseering 35 Glycoshell
22284 Hamburg, Germany
Hchst AG, Werk Gendorf Genatin extra
84508 Burgkirchen, Germany (8021 S)
Mobil Oil AG
Steinstrae 5 Frostschutz 500
20095 Hamburg, Germany
Arteco/Technologiepark, Zwijnaarde 2,
Havoline XLC
B-9052 Gent, Belgium
50 %
0302-0201AA.fm
0302-0201AA.fm
The water hardness is reduced by 1dGH if the curs. Then check once again for hardness and
following quantities of chemicals are added to pH value.
1000l of water:
- approx. 40g anhydrous trisodium phos- Testkit of the producer of the additive
phate (Na3PO4), and As far as the testkit of the supplier of the additive
- approx. 20g anhydrous sodium carbonate contains testing means to determine the charac-
(Na2CO3). teristic values of the fresh water, these can be
used.
Important!
The chemicals are to be dissolved in water, in a Check the concentration of anti-corrosion
separate tank outside the engine circuit (in order agents
for the water hardness constituents to be sepa-
rated outside the engine circulation system) and Brief specification
subsequently be gradually added via the com-
Anti-corro- Concentration
pensating tank, with the engine running. sion agent
Chemicals to increase the water hardness are In compliance with quality specification,
virtually insignificant nowadays because emulsi- Chemical
see Chapter 3.3 "Quality of engine cooling
additives
fiable anti-corrosion oils are hardly used any water", Page 3-11
longer. These chemicals only served the pur-
Initially, after filling in, 1.5 - 2% by volume;
pose of suppressing foaming in such cases. Anti-corro-
when operating conditions have stabilised
sion oil
0.5-1% by volume
Check the pH value
In compliance with quality specification,
Indicator paper, a liquid indicator, or an elec- Anti-freeze see Chapter 3.3 "Quality of engine cooling
tronic measuring unit is to be used for measur- water", Page 3-11
ing. Make sure to observe the instructions given Table 3-14 Concentration of cooling additives
by the respective supplier.
The pH value indicates the concentration of hy- Check the concentration of chemical additives
drogen ions and provides a comparative value The concentration should be checked weekly
for the aggressiveness of the water. If the pH and/or in accordance with the maintenance
value is lower than the specified limit, it can be schedule, using the testing instruments and rea-
corrected by adding sodium nitrite (NaNO2) or gents specified by the respective supplier, and
sodium hydroxide (NaOH); sodium nitrite should in accordance with the instructions issued.
be given preference. Which quantity is required
depends on the pH value found. A protection by chemical anti-corrosion agents
is only ensured if the concentration is exactly
Check the chloride ion content adhered to. In this connection, the concentra-
tions recommended by MAN B&W Diesel (see
Add exactly 5cm3 of n/10 silver nitrate solution Chapter 3.3 "Quality of engine cooling water",
(AgNO3) to 350cm3 of the water sample in the Page 3-11) are to be adhered to by all means.
glass and mix thoroughly. Add 5 drops of a 5- These recommended concentrations may differ
percent potassium chromate solution (K2CrO4). from the producers specifications.
If red colouration occurs, the chloride ion con-
tent is less than 50mg/l. For reasons of environment protection, chemi-
cal additives are almost exclusively used nowa-
If the chloride ion content is too high, add water days. Emulsifying anti-corrosion oils have lost
0302-0202AA.fm
0302-0202AA.fm
Ultrasonic
Vecom 4% 12 hrs at 50 60C
Multi Cleaner
Table 3-16 Cleaning agents for dissolving calcareous scale and rust
In general, products used for dissolving calcare- sion pitting. We therefore recommend having
ous scale deposits are also suitable for remov- the cleaning operation performed by a firm
ing rust. Table 3-16, Page 3-24, lists appropriate specialising in this field.
agents in alphabetical order. Products of other
Carbon dioxide bubbles which form in the disso-
manufacturers may also be used as long as their
lution process of the calcareous deposits may
properties are comparable. The manufacturers
obstruct the access of the cleaning agent to the
instructions for use are likewise to be strictly ob-
water scaling. It is, therefore, absolutely neces-
served. Prior to cleaning, check whether the
sary to circulate the water containing the clean-
agent concerned is suitable for the materials to
ing agent so that the gas bubbles are carried
be cleaned. The agents listed in Table , Page
away and can escape. The duration of the clean-
3-24, are also suitable for stainless steel
ing process depends on the thickness and com-
position of the deposits. For guide values,
In case of emergency please see Table , Page 3-24.
Only in exceptional cases, if none of the special
agents the application of which does not After cleaning
present problems is available, calcareous de-
Following the cleaning of cooling spaces using
posits may be removed by using aqueous hy-
cleaning agents, the system has to be flushed
drochloric acid or amido sulphur acid as a
several times. In doing so, make sure to replace
means of emergency. The following is to be ob-
the water. Where acids have been used for
served for application:
cleaning, subsequently neutralise the cooling
Heat exchangers made of stainless steel system with appropriate chemicals, and then
must never be treated with aqueous hydro- flush it. When this has been done, the system
chloric acid. can be refilled with appropriately treated water.
Cooling systems containing nonferrous Attention!
metals (aluminium, red brass, brass, etc.)
Do not start the cleaning process before the en-
have to be treated with inhibited amido sul-
gine has dooled down. Hot engine components
phur acid. This acid should be added to the
are not allowed to be charged with cold water.
water at a concentration of 3 - 5%. The tem-
Prior to proceeding to refilling the cooling water
perature should be 40 - 50C.
system, make sure that the venting pipes are
Aqueous hydrochloric acid may only be used open. Clogged venting pipes obstruct the es-
for cleaning steel pipes. The use of hydro- cape of air and involve the danger of thermal
chloric acid for system cleaning always in- overloading of the engine.
volves the risk of acid residues remaining in
0302-0203AA.fm
This guideline specifies the basic demands a regulating effect on the concentration constit-
made on cooling water for cooling tower opera- uents of the circulating water. The amount of the
tion. Should the cooling tower manufacturer water to be exchanged depends on the water
make further demands on the water quality, quality and has to be chosen as to ensure con-
these requirements must, by all means, be ob- stant compliance with the limit values specified
served. for the circulating water (see Table 3-17, Page
3-26).
Moreover, it must be taken into consideration
that additional demands will be made on the wa-
ter quality depending on the material of the cool- Additive water
ers, which are applied with water. Additional The system water losses caused by blowing
requirements for the cooling water made by the down, evaporation or leakages must be re-
cooler manufacturer must also be observed. placed by continuous additive water topping
during operation. The required amount of addi-
General tive water depends on the quality of the additive
water and the climatic site conditions.
The raw water system with cooling tower re-
cooling concerns an open circulation system, Certain demands have to be made on the addi-
which dissipates the heat absorbed from the tive water quality, which is based on the require-
water by evaporation into the cooling tower. ments for circulating water taking the
This results at the same time in a continuous wa- concentration degree into consideration. If the
ter loss due to evaporation. In order to restrict required water quality cannot be achieved, the
the incurring salt concentration, a certain water water has to be treated chemically (e.g. soften-
amount must permanently be topped as addi- ing or hardness stabilisation) or mechanically, if
tive water. necessary. Otherwise
Water losses due to evaporation and blowing deposits due to precipitation of hardly solu-
down (depending on the additive water quality) ble salts,
may amount up to 3% of the circulating water
sediments of disperse solid substances,
quantity.
corrosion,
Blowing down growth of micro organisms
An increasing evaporation loss results in a high- are to be expected.
er concentration of the salts and the suspended
substances in the water and, therefore, in an in- The cooling tower should, at least, be run with a
creasing tendency to corrosion and the forma- concentration by factor 2. Higher concentra-
tion of deposits in the system. In addition, the tions are, in general, more economic. In order to
raw water absorbs impurities from the ambient permit this, the content of substances must not
air. Deposits have a negative effect on the heat exceed half of the amount of the contents per-
dissipation in the coolers and the control system mitted for circulating water. For the absolute
function. minimum requirements, please see Table 3-17,
Page 3-26.
In order to avoid excessive concentration, a part
0302-0204PA.fm
1)
Water treatment Minimum requirements in the case of concentration
factor 2. At a higher concentration the values are ac-
Depending on the water quality, various treat- cordingly lower.
ment processes come into consideration: 2)
When using chemical additives, the pH values may be
located outside the specified range.
Decarbonisation, acid injection
Desalinisation Monitoring of the water quality
Cooling water conditioning (chemical treat- pH Value, water hardness and conductivity of
ment). the circulating water should, at least, be meas-
By using special chemicals, so-called stabilisers ured every 2 weeks. Based on the conductivity,
and conditioners, deposits and corrosion in the it can be checked whether the prescribed con-
cooling water circuit can largely be controlled. centration factor is kept. Regular checks must
These means permit operation at increased include the values stated in Table 3-17, Page
concentration and, therefore, a reduction of the 3-26.
required additive water.
Utilisation of biocides
When using chemical additives for cooling water
conditioning, the cooling tower manufacturer is Intensive venting of the water in the cooling tow-
to be contacted. er and insulation will, above all, during the warm
season, cause algeas and microorganisms,
Quality guidelines for circulating and additive which clog the cooling system, support corro-
water sion and clearly reduce the cooling efficiency.
Growth by algeas, shells and bacteria colonies
Circulating water Additive water 1) must, therefore, be eliminated by vaccination
with chlorine or effective biocides.
Appearance Colourless, clear, Colourless, clear,
no sediments no sediments The selection and application of biocides de-
pends on the occurring microorganisms. Close
pH value 2) 7.5 - 8.5 -
cooperation with the manufacturer, resp. suppli-
Total salt content <2,500ppm <1,250ppm er, would be recommendable as they dispose of
suitable test processes for micro organism de-
Conductivity <3,000S/cm -
tection as well as the necessary experience.
Calcium >20ppm >10ppm
IMO Marine Environment Protection Committee In the fuel ordering form, the limit values as per
of 1 Jan. 92. Table 3-19, Page 3-29, which have an influence
on the engine operation, should be specified, for
Leaked oil collectors example in the bunkering or charter clause.
Please note the entries in the last column of Ta-
Leaked oil collectors into which leaked oil and
ble 3-19, Page 3-29, because they provide im-
residue pipes as well as overflow pipes of the
portant background information
lube oil system, in particular, must not have any
connection to fuel tanks. Leaked oil collectors
Important:
should empty into sludge tanks.
Fuel oil characteristics as stated in analysis re-
Specifications sults - even if they meet the above mentioned
requirements - may be not sufficient for estimat-
For the usability of fuels of certain specifica-
ing the combustion properties of the fuel oil. This
tions, Table 3-18, Page 3-28, is valid. In Table 3-
means that service results depend on oil proper-
19, Page 3-29, the limit values to be complied
ties which cannot be known beforehand. This
with in each case are stated.
especially applies to the tendency of the oil to
The heavy fuel oils ISO F-RMK 35/45/55, with a form deposits in the combustion chamber, gas
maximum density of 1010kg/m3, can only be passages and turbines. It may, therefore, be
used if appropriate modern separators are avail- necessary to rule out some oils that cause diffi-
able. culties.
will be prevented. The specified injection viscos- The separators must be of the self-cleaning
ity and/or the necessary fuel oil temperature up- type (i.e. with automatically induced cleaning
intervals).
Separators of the new generation are to be which the manufacturers of these separators
used exclusively; they are fully efficient over a take as a basis and which they also guaran-
large density range without requiring any tee.
switchover, and are capable of separating
The manufacturer specifications have to be
water up to a heavy fuel oil density
adhered to in order to achieve an optimum
of 1.01g/ml at 15C.
cleaning effect.
Table 3-20, Page 3-31, shows the demands
made on the seoarator. These limit values
1 separator for
100% throughput
1 separator (standby) for
100% throughput
Layout of the separators is to be in accord- water and inorganic foreign particles in the
ance with the latest recommendations of the heavy fuel oil are reached at the entry into the
separator manufacturers, Alfa Laval and engine.
Westfalia. In particular, the density and vis-
The results obtained in practical operation re-
cosity of the heavy fuel oil are to be taken into
veal that adherence to the above values
consideration. Consulting MAN B&W Diesel
helps to particularly keep abrasive wear in the
is required if other makes of separators come
injection system and in the engine within ac-
up for discussion.
ceptable limits. Besides, optimal lube oil
If the cleaning treatment prescribed by MAN treatment must be ensured
B&W Diesel is applied, and if the coorect sep-
arators are selected, it can be expected that
the results given in Table 3-20, Page 3-31, for
Table 3-20 Obtainable contents of foreign matter and water (after separation)
Under certain conditions, high-temperature heavy fuel oil to approx. 10C above the pour
corrosion may be prevented by a fuel additive point.
Figure 3-2 Nomogram for the determination of CCAI - assignment of CCAI ranges to engine types
CCAI can also be calculated with the aid of the following formula:
0302-0301AA.fm
Sulphuric acid corrosion The use of fuel additives during the guarantee
period is rejected as a matter of principle.
The engine should be operated at the cooling
water temperatures specified in the operating Additives currently in use for Diesel engines are
manual for the respective load. If the tempera- listed in Table 3-21, Page 3-35, together with
ture of the component surface exposed to the their effect on engine operation.
acidic combustion gases is below the acid dew
point, acid corrosion can no longer be sufficient-
ly prevented even by an alcaline lubricating oil.
Dispersants/stabilizers
If the lube oil quality and engine cooling meet
the respective requirements, the BN values (see Pre-combustion Emulsion breakers
Chapter 3.2 "Quality of lube oil for heavy fuel oil Biocides
operation (HFO)", Page 3-7) will be adequate, Combustion catalysts (fuel econ-
depending on the sulphur concentration in the Combustion
omy, emissions)
heavy fuel oil.
Ash modifier (hot corrosion)
Post-combustion Carbon remover (exhaust sys-
Compatibility
tem)
The supplier has to guarantee that the heavy fuel
oil remains homogenous and stable even after Table 3-21 Additives to heavy fuels - Classification/
the usual period of storage. If different bunker effects
oils are mixed, separation may occur which re-
sults in sludge formation in the fuel system, large
quantities of sludge in the separator, clogging of
filters, insufficient atomisation and highresidue
combustion.
In such cases, one refers to incompatibility or in-
stability. The heavy fuel oil storage tanks should
therefore be emptied as far as possible prior to
re bunkering in order to preclude incompatibility.
Examinations
Sampling
To be able to check as to whether the specifica-
tion indicated and/or the stipulated delivery con-
ditions have been complied with, we
recommend a minimum of one sample of each
bunker fuel to be retained, at least during the
guarantee period for the engine. In order to en-
sure that the sample is representative for the oil
bunkered, a sample should be drawn from the
transfer pipe at the start, at half the time and at
the end of the bunkering period. Sample Tec,
supplied by Messrs Mar-Tec, Hamburg is an ap-
propriate testing kit for taking samples continu-
ously during the bunkering.
Analyse samples
The samples received from the bunkering com-
pany are frequently not identical with the heavy
fuel oil bunkered. It is also appropriate to verify
the heavy fuel oil properties stated in the bunker
documents, such as density, viscosity, pour
point. If these values should deviate from those
of the heavy fuel oil bunkered, one runs the risk
that the heavy fuel oil separator and the preheat-
ing temperature are not set correctly for the giv-
en injection viscosity. The criteria for an
economic engine operation with regard to heavy
fuel oil and lubricating oil may be determined
with the help of the MAN B&W Diesel Fuel and
Lube Analysis Set.
Our department for fuels and lube oils (Augs-
burg Works, Department QC) will be glad to fur-
nish further information if required.Additives to
heavy fuel oils: Classification/effects
0302-0301AA.fm
1.5
Cinematic viscosity / 40C mm2/s ISO 3104
6.0
Filter ability1)
in summer 0
DIN EN 116
in winter C -12
Other specifications:
Supplementary information
Investigations
Fuel analyses are carried out in our chemical
laboratory for our customers at cost price. For
examination a sample of approx. 1dm3 is re-
quired.
0302-0303AA.fm
0302-0401AA.fm
pH Value, daily
During the warranty period and in the case of ex-
isting maintenance contracts, only the products Conductivity, daily
Hardness, daily
Iron content
Acid capacity of up to pH 8.2 (p value).
Additive concentration (according to manu-
facturer specifications)
The following values of the condensate are to be
checked and documented regularly:
pH Value, daily
Conductivity, daily
Hardness
Iron content
Additive concentration (according to manu-
facturer specifications).
0302-0501AA.fm
Integrated lube oil service-tank with nominal The engine requires a flywheel.
filling of approx. 1l/kW according to MAN A standard coupling is used. Size and rubber
B&W Diesel standard. quality are determined by the torsional vibra-
All necessary connections for the lube oil sys- tion calculation.
tem are integrated in defined positions at the For maintenance and adjustment works a
frame as pipe sockets. The turbocharger turning gear is installed at the frame. If neces-
drains are connected to the frame tank during sary, the turn drive engages with the sprocket
production. of the flywheel.
On the counter coupling side of the frame The power train (flywheel and coupling) is
fastening plates serve to fasten pipe of the covered by a flywheel cover which has venti-
connecting pipes via adapters. lation holes in the coupling area in order to al-
The base board of the frame has bores to se- low heat dissipation. The flywheel cover is
cure the spring vibration dampers fixed un- usually fixed onto the concrete foundation.
derneath the base board (when required in
Transport
earthquake regions).
The genset is usually transported on a low-bed
Genset trailer. If engine and frame are transported sep-
The genset is placed on standardised steel arately a transport oil sump is mounted under
spring vibration dampers. the engine to protect the interior of the crank-
case from pollution.
Depending on site conditions (earthquakes)
with or without additional visco dampers. To lift the genset the standard MAN B&W Diesel
lifting device is hung to the crane, see Figure 4-
0402-0101PD.fm
For transport the engine is secured against shift- The admissible traction per lifting loop in di-
ing. rection transversal to the engine direction is
maximum 20 t at the V-genset and 15 t at the
Moving the genset without crane L-genset, resp.
Moving the genset without a crane, e.g. onto Longitudinal as well as transversal movement
a displacement slant to transfer it into the is possible with the lifting loops provided that
powerhouse, can be done by means of four the admissible traction is not exceeded.
hydraulic jacks that are to be set under the
frame consoles beneath the lifting loops. Moving, aligning the genset on the founda-
tion and grouting the alternator.
The lifting loops are to be used to move the
genset. Always using all four loops at the After shifting the genset onto the foundation the
same time. genset is to be set onto the steel spring vibra-
tion dampers and the alternator is aligned with
the engine and grouted.
Figure 4-4 Genset with maintenance platform and lube oil purifier - engine V48/60
0402-0101PD.fm
The rubber quality of the coupling is determinated by torsional vibration calculation Typical DIMENSIONS IN MM
TYPE T1 H1 H2 R
Typical DIMENSIONS IN MM 12V 48/60 CDUW 180 -1266 320 510 1365
DK M L 14V 48/60 CDUW 200 -1278 350 480 1365
12- 14V 48/60 d= 1685 h6 688,6 520 18V 48/60 CDUW 225 -1292 390 440 1365
18V 48/60 d= 1790 h6 753,0 570
TYPICAL DIMENSIONS IN MM
TYPE A B C D
0402-0101PD.fm
Figure 4-2 Flywheel cover - engine V48/60 Figure 4-3 Turnin gear - engine V48/60
D
X
Depending on the weight of the genset and in ad-
dition to the earthquake zone the spring/damper
unit equipment has to be designed in a combina-
tion of I and II.
X = adhesive pad; D = thread M20 for transport
A Optional with 400mm, 640mm or 740 mm A Optional with 300mm, 445mm or 590mm
0402-0101PD.fm
B Optional with 352mm, 592mm or 692mm B Optional with 252mm, 397mm or 542mm
H Nominal operating height = 340 mm H Nominal operating height = 340mm
1) Spring element Figure 4-6 Typical damper- spring unit - engine V48/60
2) Damper element
0402-0101PD.fm
Engine 48/60
0502-0102PD.fm
Figure 5-1 Equipment schedule for lube oil system - engine 48/60
Engine V 48/60
0502-0102PD.fm
Figure 5-2 Schematic diagram for lube oil system - engine V48/60
Quality requirements
The cooling medium consists of treated cooling
water.
See
Chapter 3.3 "Quality of engine cooling wa-
ter", Page 3-11.
Chapter 3.4 "Checking cooling water", Page
3-19.
Chapter 3.5 "Cleaning cooling water", Page
3-23.
Anti-freeze for cooling water see
Chapter 3.3 "Quality of engine cooling wa-
ter", Page 3-11.
Engine 48/60
0502-0202PD.fm
Figure 5-3 Equipment schedule for HT cooling water circuit - engine 48/60 (Radiator cooling system)
Engine V 48/60
0502-0202PD.fm
Figure 5-4 Schematic diagram for HT cooling water circuit - engine V48/60 (Radiator cooling system)
Note
Main operation conditions
If anti-freeze is used belated, contact MAN B&W
Cooling water temperature Diesel for reduction of cooling capacity and
after engine ....................depends on engine compatibility with corrosion protection. This
performance and note applies only if the plant is not planned for
site conditions anti-freeze.
Cooling water pressure
before engine ................................. 2 ... 4bar
Quality requirements
The cooling medium consists of treated cooling
water.
Quality requirements for cooling water and
cooling water treatment see Chapter 3.3
"Quality of engine cooling water", Page 3-11.
Checking cooling water see Chapter 3.4
"Checking cooling water", Page 3-19.
Cleaning the cooling water system see Chap-
ter 3.5 "Cleaning cooling water", Page 3-23.
Anti-freeze for cooling water see Chapter 3.3
"Quality of engine cooling water", Page 3-11.
Engine 48/60
0502-0204PD.fm
Figure 5-5 Equipment schedule for LT cooling water circuit - engine 48/60 (Radiator cooling system)
Engine V 48/60
0502-0204PD.fm
Figure 5-6 Schematic diagram for LT cooling water circuit - engine V48/60 (radiator cooling system)
0502-0204PD.fm
Cooler HE005.
Engine 48/60
0502-0206PD.fm
Figure 5-7 Equipment schedule for nozzle cooling water circuit - engine 48/60
Engine V 48/60
0502-0206PD.fm
Figure 5-8 Schematic diagram for nozzle cooling water circuit - engine V 48/60
0502-0301PD.fm
The ring line generates an increased pressure by The engine is generally run up in Diesel oil oper-
an overflow valve and is connected to the at- ation. When reaching the parameters
mosphere via the service tank, whereas the engine load 30%
main fuel oil system is a closed pressureised
HFO-temperature in closed circuit system
system.
60C
Design criteria engine cooling water temperature 90C
Generally, the ring line system feeds the main the engine can be switched to heavy fuel oil op-
fuel oil systems of up to four engines. eration.
In HFO-operation the fuel oil viscosity is kept at
12-14cSt by the viscosimeter VI001 and the fi-
Mesh size of double filter in HFO- module
nal heater H004 with the associated control de-
................ .................................................. 34m
vice.
Fuel oil circulation in the main fuel oil system
When switching off the engine it is generally
........ ......................3 to 5 x engine consumption
switched back to Diesel oil operation and the
......................................................at 100% load
main fuel oil system is filled by Diesel oil.
Components The engine can be switched off and run up again
in heavy fuel oil operation if the engine systems
Main components are kept at operating temperature and the me-
Ring line system dia are circulated during engine downtime.
The ring line system is divided into: The Diesel oil heat exchanger HE007 is to be ac-
tivated if Diesel oil operation is to be run for a
- Diesel oil ring line longer time frame.
- HFO ring line
Fuel oil quality
Main fuel oil system
MDO-quality see Chapter 3.8 "Quality of Ma-
The main fuel oil system consists essentially
0502-0401PD.fm
Engine 48/60
0502-0402PD.fm
Figure 5-10 Equipment schedule for fuel oil system - engine 48/60
Engine V 48/60
0502-0402PD.fm
Figure 5-11 Schematic diagram for fuel oil system - engine V48/60
Purpose Cool.
The combustion air system serves to Dry.
supply the Diesel engine with combustion air Also see Chapter 3.11 "Quality of intake air
of the necessary amount and quality during (combustion air)", Page 3-43.
all loads and environmental conditions,
reduce the level of the sound.
System see Chapter 6.1.4 "Combustion air sys-
tem", Page 6-31 and typical air intake module
Feature Figure 6-58, Page 6-66 and Figure 6-59, Page
The combustion air system is a flow rate system. 6-67.
Components
Weather protection with bird protection grat-
ing AIR011 at system inlet.
Rotary oil bath filter FIL007.
Sound absorber SL001 to adsorb noise
caused by intake air flow. Its designs and
performance depending on the demands.
Usually MAN B&W Diesel offers silencer per-
formances of 30dB(A), 40dB(A) and 50dB(A).
Intake piping.
Compensator designed for negative pres-
sure.
Weather protection, rotary oil bath filter and
sound absorber are delivered as a unit.
Pressure
The admissible negative pressure in the sys-
tem is 20mbar.
Temperature
The intake air temperature may not exceed or
undershoot the values defined for the engine
installation power.
Clean.
Engine 48/60
0502-0502PD.fm
Figure 5-12 Equipment schedule for intake air system - engine 48/60
Engine V 48/60
0502-0502PD.fm
Figure 5-13 Schematic diagram for intake air system - engine V48/60
The following points are to be taken into consid- Drainage of the system.
eration when designing and operating the ex- Compensator 1EB6501 / 2EB6501 to take up
haust gas system:
- Changes of length of components due to
Distances to flammable objects required by temperature changes.
local fire regulations are to be observed.
- Vibration amplitudes if the engine is elasti-
Sufficient insulation of the exhaust gas pipe cally supported.
and the silencer is to be provided in order to
Insulation as protection against contact and
- reduce transition of air-borne noise to reduce heat radiation.
- reduce fire danger and risk of accident Also see Chapter 6.2.6 "Exhaust gas mod-
- reduce pipe corrosion ule", Page 6-69.
Engine 48/60
0502-0602PD.fm
Figure 5-14 Equipment schedule for exhaust gas system - engine 48/60
Engine V 48/60
0502-0602PD.fm
Figure 5-15 Schematic diagram for exhaust gas system - engine V48/60
0502-0602PD.fm
6.1.1.2 Pumps
MAN B&W Diesel delivers the following pumps. Attention!
Centrifugal pumps must be filled with medium
Centrifugal pumps prior to initial start-up in order to ensure proper
Usually used for wetting of the slide ring seal (mechanical seal).
All waters and
Avoid dry running by all means!
Circulation of thermal oil.
To avoid shaft leakages centrifugal pumps are
generally equipped with non-cooled slide ring
seals.
The viscosity of the delivery medium strongly in-
fluences
Efficiency
Characteristic
Height of conveyance
of the centrifugal pump.
Therefore MAN B&W Diesel uses centrifugal
pumps only to advance water.
Centrifugal pumps are not self-priming.
Centrifugal pumps have an efficiency of 75% ...
85%. Pumps with a flow rate of 500m/h have
an efficiency of approx. 80% ... 85%. Smaller
pumps have smaller efficiencies.
Centrifugal pumps must always be adjusted to
the conditions at the site.
Centrifugal pumps
1 Operating point
0601-0101PA.fm
1 Casing
2 Driving cover
3 End gear with Bulton relief valve
4 Gear shafts
5 Bearing bushes
6 Radial shaft packing ring
7 Round packing ring
Attention!
Gear pumps must be filled with oil prior to initial
start-up in order to ensure the required surface
lubrication of the rotating parts as well as proper
wetting of the seal (simmer ring)
0601-0101PA.fm
Thermal oil (fill /drain). The precisions made threads of the rotor seal
against each other and the rotor bores, forming
To avoid shaft leackages screw pumps are a series of enclosed chambers which move the
equipped with non- cooled slidering gaskets fluid uniformly at constant axial velocity. The lin-
ear movement of the fluid makes the pump suit-
Note able for direct connection to high speed motors
For screw pumps and ensures an excellent suction capability.
Screw pumps
mm mm mm mm mm mm kg kg
Operating points 1 2 3 4
speed n (min -1) 1450 1450 1450 1450
viscosity v (mm2/s) 600 300 150 70
diff.press p diff (bar) 8 8 8 8
theor. vol (l) 6,47 6,47 6,47 6,47
flow rate Qa (l/min) 9379,7 9379,7 9379,7 9379,7
fl. rate reduce (%) 0,0 0,0 0,0 0,0
flow rate Q (l/min) 9305,1 9274,2 9230,5 9161,4
power demand (kW) 203,7 186,5 173,0 161,6
to viscosity
Attention!
Screw pumps must be filled with oil prior to ini-
tial start-up in order to ensure the required sur-
face lubrication of the rotating parts as well as
proper wetting of the slide ring seal (mechanical
seal).
Diaphragm pumps
Used for
Sludge (compressed air of approx. 7bar nec-
essary).
Diaphragm pump
1 Pressure blower
2 Upper ball valve
3 Diagraphm
4 Product chamber
5 Air outlet
6 Lower ball valva
7 Upper ball valve
8 Pneumatic control valve
9 Air chamber
10 Lower ball valve
11 Suction casing
0601-0101PA.fm
Hose pump
2) During the rotation the product inside the 4) This volume is delivered to the pressure outlet
hose (liquid or gas) is forced towards the pres- whilst the same amount is simultaneously drawn
sure outlet. this causes a pressure drop in the in through the suction fitting (Figure 3 and 4).
suction side and product is then drawn in.
0601-0101PA.fm
Hose Pumps
Hose pump
All pump size with flange Glandless capable of One- piece rotor sliding,
connection. Other types of dry- running, dry blocks easily adjustable
connection possible self- priming
Hose and all moveable parts Compact structural shape Special shaped pump hose
lubricated by glycerine filling Pressure proof casing in different elastomers,
reinforced by textile fabrics
6.1.1.3 Strainer
Strainer
Strainers are used as pump protection on the in-
take side of the pump for
Lube oil
Heavy oil
Diesel oil
Vapour
Condensate
Mesh size: 500 m.
See following figure.
1 Body
2 Screen
3 Gasket
4 Cover
5 Stud
6 Hexagonal nut
7 Empty screw
0601-0102PA.fm
6.1.1.4 Filter
Running- in filter
Running-in filter for lube oil.
On the pressure side of the circulating pump,
temporary for lube oil, installed at the engine.
Mesh size: 37 m.
Automatic filter
Interval flush filter
Used in HFO ringmain pipe.
Mesh size: 34 m.
Back flushing with pressure air 10bar.
One chamber is always in stand-by or in back
flushing process, dependent on the pressure dif-
ference in the filter.
See function of filters below.
General survey of strainer/filter mesh sizes for stationary Diesel power plants
30 m Automatic filter (permanent flushing) Lube oil main filter (indication filter insert 100 m
included)
Tube Type
Used for Suitable for higher temperatures and pres-
sures as no soft sealing is used.
Heavy oil preheating (HFO-module).
1 Tube flange
2 U- Tube
3 Bafle plates
4 Sealing strip
5 Distance tube
6 Nut
7 Stay rod
0601-0102PA.fm
Radiator cooler
Used for
Waters
Lube oil
Heat transfer medium (vapour, hot water,
thermal oil).
Cooling tower
See separate Chapter 6.1.3 "Cooling tower
cooling system (forced- air- cooled)", Page
6-30.
0601-0102PA.fm
- Engine cooling water ................. HT-circuit The flow rates and temperatures of the media to
be cooled are given in the schematic diagrams
- Charge air cooler, stage 1.......... HT-circuit and the corresponding description
0601-0201PA.fm
Engine 32/40 35 45
Oil temperature at
engine inlet: 65C 40 50
Oil cooler in LT-cir-
45 55
cuit
Engine 48/60 35 45
Oil temperature at
engine inlet: 55C 40 47
Oil cooler in LT-cir-
cuit
MAN B&W Diesel uses a common cooler sup- even tolerances of the cooler support must be
port frame for the radiator cooler bundles. In or- ensured.
der limit cooler bundle distortion, distance and
Please see illustration below.
Engine Type 18V 32/40 (100% load) 18V 48/60 (100% load)
Water flow rate LT- circuit m3/h 123 165 224 286
Water flow rate HT- circuit m3/h 158 218 318 444
Table 6-5 Orientation assistance for estimation the required amount of raw- and make- up water
Water temperature before CT 48C
Calculated on a concentration factor 2
0601-0301PA.fm
Purpose
The combustion air modules and components
Figure 6-32 Rain protection for intake air filter
serve to:
Protect the engine against weather and birds
Clean the intake air
The total weather protection grid can be seen in
Absorb the sound the Drawing on the following page.
Features
MAN B&W Diesel uses Droplet Separator Profile
as rain protection
Separation technology
The streamlined separator profiles deflect the
droplet laden gas stream, as a result the monu-
mentum of the droplet causes them to impinge
onto the profiles surface. The droplets coalesce
together form a liquid film, the influence of grav-
ity causes the liquid to drain to the bottom of the
profiles. Specially sharped separation chambers
improve performance by enhancing the separa-
tion of finer droplets and ensuring problem for
discharge of liquid.
To avoid the flooding of the profiles and the pos-
sibility of re- entrainment of the separated liquid,
the height of the profile sections is normally lim-
ited to 2,500 mm.
The following graph illsustrates the descripted
technologie.
0601-0401PA.fm
Size of intake air filter a adequate supply of adhesive oil. The filter
panels move vertically upward across the
The intake air filters are to be designed for the
front face of the housing forming a continu-
respective combustion air quantity of the die-
ous sealed curtain. They are then carried
sel engine
across the housing as the chains engage with
Consult MAN B&W Diesel to have the values carrier sprockets located in the top of the
calculated by the program "Projedat" casing and maintain the same vertical face as
Generally, the necessary gross area of the in- they travel downward on the clean side of the
take air filter is calculated as follows: filter.
Intake air Q [m3/h] / flow rate v [m/sec] = A [m2] On reaching the adhesive oil tank, the parti-
cles are submerged and thoroughly cleaned
The flow rate should be within 2,5 m/sec to by agitation prior to emerging from the bath
3 m/sec re- oiled and drained for re- entry the incom-
ing airstream.
Separation efficiency of oil bath rotary filter
At all stages of operation the filter panels
Degree of separation of an oilbath rotary filter is present the same face of filter media to the in-
given in the following graph. coming airstream.
The double panel bank and controlled curtain
movement ensures positive ellimation of oil
"carryover" with the filtered air.
Operation
Thus the filter panels travel a distance of ap-
With the power supply connected and control prox. 50mm during the 6 seconds and then
panel switched on, a timer circuit on an elec- remain stationary for 30 minutes. This allows
tronic control board will operate after a 60 time for any excess oil to drain from the filter
seconds delay, switching the power onto the panel mesh media back down into adhesive
0601-0401PA.fm
Recommended adhesive oils mesh), reduced filter effect and reduced filter
regeneration (reduced adhesion forces, re-
The viscosity of oil generally depends on the
duced resolving of oil film in bath).
temperature and decreases with decreasing
temperature. The oil is therefore to be adapt- At oil change the oil is transferred, cleaned
ed to the ambient temperature according to and kept until the next use.
the manufacturers instructions, see table be-
low. A wrong viscosity leads to increased
pressure loss of the filter (thicker oil film in the
-10C to +6C Shell Tellus 10 Shell Morlina 10 Mobil DTE 11 M EssoNUTO H 10 ISO 10
-5C to +16C Shell Tellus 15 Shell Morlina 22 Mobil DTE 11 M Esso NUTO H 15 ISO 15
-6C to +27C Shell Tellus 22 Shell Morlina 22 Mobil DTE 22 M Esso NUTO H 22 ISO 22
-16C to +38C Shell Tellus 37 Shell Morlina 46 Mobil DTE 24 M Esso NUTO H 32 ISO 32
-28C to +52C Shell Tellus 100 Shell Morlina 100 Mobil DTE 27 M Esso NUTO H 100 ISO 100
Figure 6-37 Typical fix point support to reduce structure bome noise for air intake and exhaust gas pipes
Figure 6-38 Typical sliding point support to reduce structure bome noise for air intake and exchaust gas pipes
DN A=E B C D F G I S T H
mm
600 200 100 560 460 110 460 550 18-20 20 519
700 568
800 618
900 300 200 660 560 210 610 700 18-20 20 668
1000 718
1100 768
1200 828
1300
1400 400 300 820 720 310 860 950 18-20 30 928
1600 1028
0601-0401PA.fm
1700 1078
1800 1128
gine planning data (see respective engine in Figure 6-42 "Fix point for silencer and boiler to
Chapter 2 "Engine", page 2-1 and following). reduce structure born noise", Page 6-41, pro-
(Unally < 30mbar) viding information about the execution of the
support (fixed point and sliding point) of exhaust
Insulation
The insulation of exhaust gas pipe and exhaust
gas silencer is a hard cladding insulation con-
sisting of rock wool with aluminium- plate- cov-
ering.
Also see the separate drawings in chapter 6.1.4,
6.2.6/6.3.6 and at the end of this chapter.
Typical crossection of an exhaust gas absorp-
tion silencer see Figure 6-39, Page 6-40.
0601-0501PA.fm
Technical data
Service pressure p = 25 mbar
Service temperature t = 550C
With floating flanges
On both sides from steel to DIN86044
Below multi wall from steel alloy 1.4541
0601-0501PA.fm
1) Oil inlet
2) Oil outlet
3) Sludge outlet
4) Make- up closing water inlet
5) Opening water inlet
6) Water drain valve
7) Water outlet
8) Flow control disc
9) Disc stack
10) Top disc
11) Inlet for conditioning and displacement
water
Figure 6-46 Schematic illustration of a separator with Figure 6-47 Schematic illustration of a separator with
Sludge Space Monitoring System (SMS) Sludge Space Monitoring System (SMS)
during separation during ejection 0601-0601PA.fm
mm mm mm mm mm mm kg kg
V48/60 diameter
Lube oil separators for engine V48/60 The hoist should be mounted on a running rail so
that bowl parts can be moved from the separa-
Transport weight approx. 1,500kg
tor to a workbench.
Operating weight approx. 1,800kg
Do not discharge the oily sludge into the pub- Separator for Height H1 Weight of bowl
lic sewage system.
mm kg
A hoist should be installed above the separa-
tor so that the heavy bowl parts can be han- 12V 48/60 1,540 190
14V 48/60
dled more easily.
0603-0101PD.fm
18 V 48/60
litre kg mm
N1 Manhole
N2 Venting
N3 Return
N4 Outlet
N5 Outlet
0603-0101PD.fm
Components
HT cooling water module
Engine N1 N2 N3 N4 Weight
from cooler bypass expansion line to engine
mm mm mm mm kg
0603-0201PD.fm
Figure 6-50 Cooling water expansion tank - engine V48/60 empty/weight = 500kg
filled/weight = 2000kg
0603-0202PD.fm
Engine N1 N2 N3 N4 N5 N6 N7 Weight
from cooler expansion to charge from to engine to lube oil nozzle
line air cooler charge air cooler cooling
cooler water
outlet
mm mm mm mm mm mm mm kg
Nozzle cooling water module MOD005 Control and power equipment, including the
sensors, are completely accommodated in a
Purpose switch cabinet and wired to the module.
The purpose of the nozzle cooling water module
is the automatic and lasting cooling of the fuel oil
injection nozzle of MAN B&W Diesel engines at
all operating conditions of the engine in compli-
ance with applicable control on/off, safety and
environmental requirements.
Further, the module is to preheat the fuel oil in-
jection nozzles before start of the Diesel engine.
In case of nozzle preheating, the nozzel cooling
water is heated in the tank before the engine
starts. The nozzle cooling water is thus heated
and pumped to the engine and back to the water
tank.
Features
The module consists of a self- supporting frame.
the corresponding compponents are connected
by means of pipes.
The nozzle cooling water circuit is a separate
pressurized closed circulation system. A centrif-
ugal pump sucks the nozzle cooling water from
a tank and pumps it to the nozzles of the Diesel
engine through a heat exchanger with subse-
quent temperature control valve. The circuit then
leads back to the tank.
The heat exchanger is supplied with LT-cooling
water as cooling medium.
The temperature control valve keeps the nozzle
cooling water temperature upstream of the noz-
zle constant.
A test connection serves to check if the water
contains oil (nozzle leakage).
The entire module is designed for continuous
fullload and part load operation (intermittent op-
eration several times per day).
The module is designed for unmanned operation
0603-0203PD.fm
- weight 380 kg
- operating pressure max.
4 bar
- operating temperature
max 95C Figure 6-52 Noozle cooling water
0603-0203PD.fm
Figure 6-53 Cooling tower with water basin, accessgrating water pipes and raw water pumps.
Figure 6-54 Side view of cooling tower with supply and discharge cooling water pipes
0603-0301PD.fm
Figure 6-55 Cooling tower with supply and discharge cooling water pipes
0603-0301PD.fm
An automatically operated three-way valve Switch cabinet with automatic control and
serves to switch from Diesel oil to heavy oil and power device
vice versa, if necessary. Control, power device and sensors are complete
The fuel oil flows through a fuel oil meter to a cabled in the switch cabinet.
mixing tank. From there the supply pump deliv- .
ers the fuel to the final preheater, the viscosime-
ter and then to the Diesel engine. The
viscosimeter controls the heat energy supply to
the preheater so that the adjusted fuel oil viscos-
ity is achieved during heavy oil operation. The
surplus fuel oil flowing back from the Diesel en-
gine is lead to the mixing tank. Fresh fuel oil is
added to the surplus fuel which is then again
added to the fuel oil circuit.
The entire Diesel fuel oil module is to be run in
continuous fulload and part load operation (in-
termittent several times per day).
The module is designed to be operated fully au-
0603-0401PD.fm
Components
Weather and bird protection grating AIR011
Oil bath rotary filter FIL007
Silencer SL001
- 30 dB(A),
- 40dB(A) or
- 50dB(A)
Air intake pipes
Eng.
Silencer Dimension Weight Intake Air
30dB(A) each air Ve-
L L1 B C H h1 h2 DN Z
locity
mm kg m/h m/s
12V 48/60 2,570 2 x 900 38,500 2,5
14V 48/60 3,347 2,187 1,895 1,800 2,440 2,520 3,582 2 x 1,000 2,041 3,200 45,000 2,9
18V 48/60 3,797 2,687 1,895 1,800 2,948 2,980 4,090 2 x 1,100 2,041 3,500 58,000 3
Table 6-14 Measures table for intake air module - 40dB(A) and 50dB(A)
Note
Longitudinal welds to be arranged at the top line of
pipes. Flanges at right angles with the pipe axle.
Position of the bores for the flanges acc. to DIN
2501. Surface protection acc. to AN 410.
Engine is resilient supported. Between the con- tional measures might be required. See MAN
nection engine and duct, there must be an ex- quality requirements for intake air 3.3.11. Should
pansions joint for fre movement of engine, which additional sound- absorption measures be nec-
0603-0501PD.fm
must be capable of bearing vacuum. The admis- essary, a silencer with higher damping perform-
sible pressure loss is 20 mbar max. In case of ance might have to be selected.
high dust concentration in the intake air, addi-
0603-0501PD.fm
Note
Longitudinal welds
to be arranged at
the top of pipes.
Flanges at right
angles with the pipe
axle. Position of
the bores for the
flanges acc. to DIN
2501. Surface
protection acc. to
AN 410.
ENGINE IS RESILIENTLY SUPPORTED. BETWEEN THE CONNECTION ENGINE AND DUCT, THERE MUST BE AN EXPANSIONJOINT
FOR FREE MOVEMENT OF THE ENGINE AND FOR THERMAL EXPANSION OF DUCT BETWEEN SILENCER AND ENGINE. NEAR THE
EXPANSIONS JOINT; THE DUCT MUST BE SUPPORTED: THE EXPANSIONS JOINT HAS TO BE PRE- STRESSED LATERALLY IN COLD
CONDITION BY ABOUT 50% OF THERMAL EXPANSION: THE EXHAUST GAS TEMPERATURE IS APPROX: 400C: THE COMPLETE
PRESSURE LOSS IN THE EXHAUST GAS SYSTEM SHOULD NOT EXCEED 30MBAR.
0603-0601PD.fm
Moments (M1, M [Nm] 10000 11700 Figure 6-61 Maximum admissible forces and moments
M2, M3) on turbine outlet casing
Cyl.No. dB DN 2 DN 1 D C Weight
kg
mm
12V 48/60 25 4664 3900
1300 1300 2200
35 6179 5750
14V 48/60 25 5171 5045
1400 1400 2300
35 6672 6535
0603-0601PD.fm
0603-0601PD.fm
0603-0601PD.fm
The lube oil supply system consists of the fol- Storage tank vent pipe.
lowing main components: The vent pipe is located at the highest point
Screw type, electric motor driven unloading on the storage tank, allowing any gases to
pumps 1P059 and 2P059 (1 x operation and vent to the atmosphere.
1 x stand-by), modular mounted together Maintenance tank vent pipe (engine 48/60
with pipe work, valves and mesh type filter only).
(MOD017).
0701-0101PA.fm
Water softening plant T040 provides sof- The following auxiliary systems are supplied
tened water for the nozzle cooling, engine with softened and treated water:
cooling and boiler feedwater systems. HT / LT expansion tank.
Water storage tank T039 with vent pipe. Here Complete with pressure relief valve for main-
chemicals are added for protection against taining the required pressure.
corrosion. The water is for the nozzle cooling,
engine cooling (HT) and charge air cooling Nozzle cooling water tank.
(LT) water systems. For storage of softened and treated water.
When operating the plant, the level in the Engine turbocharger.
storage tank T039 must lie at the lower level.
Softened water is supplied for turbocharger
This is to:
water washing.
- Make up of the leaking water in the individ-
0701-0201PA.fm
ual system.
Quality requirements
The cooling water is to be treated in accordance
with the following guidelines:
Quality requirements for cooling water and
cooling water treatment see Chapter 3.3
"Quality of engine cooling water", Page 3-11.
Checking cooling water see Chapter 3.4
"Checking cooling water", Page 3-19.
Cleaning the cooling water system see Chap-
ter 3.5 "Cleaning cooling water", Page 3-23.
Anti-freeze for cooling water see Chapter 3.3
"Quality of engine cooling water", Page 3-11.
The engine cooling water, like the fuel oil and
lube oil, is a medium that must be carefully se-
lected, treated and controlled. Otherwise, corro-
sion and cavitation may occur on the walls of the
cooling system. Such deposits would impair the
heat transfer capability of the components and
thus result in thermal overload.
Leakage losses are to be replaced by treated
water.
0701-0201PA.fm
0701-0301PA.fm
Purpose Components
The heavy fuel oil supply system serves to:
Main components
Receive, store and supply sufficient amounts
of heavy fuel oil to ensure continuous, unin- The heavy fuel oil supply system consists of the
terrupted operation of the plant. following main components:
Run the engine during normal HFO operation. Screw type, electric motor driven unloading
pumps 1P038 and 2P038 (1 x operation and
1 x stand-by), modular mounted together
Features
with pipe work, valves and mesh type filter.
The heavy fuel oil is delivered by tanker, stored
The truck would connect to the unloading
in a storage tank and pressure fed to the en-
pump module via a hose with DN80 connec-
gines. The heavy fuel oil supply system is of the
tion.
closed circuit type designed with a pressurised
ringmain pipe work system. Heavy fuel oil storage tanks 1T016 and
2T016, normally steam heated, located in the
The fuel flows from storage tank T016 via the
tank farm.
supply pump P038 to the buffer tank T059 pass-
ing through the 3-way changeover valve. From The tanks are sized for 15 or 30 days capac-
the buffer tank T059 the fuel flows to the purifier ity. One tank is for receiving and settling fuel
CF002 by delivery pump P015 and then from when the other is used for supplying fuel to
here back to the clean oil daily service tank the plant and vice versa.
T022. There is an overflow from T022 to T059.
When operating the plant the heavy fuel oil
Once the high level in tank T059 is activated the
level must lie between the minimum and
3-way changeover valve changes back to tank
maximum gauges of the storage tanks.
T016 allowing the fuel to circulate around the
storage tank and the purifier. Once the clean oil Screw type, electric motor driven heavy fuel
daily service tank T022 asks for more oil the sys- oil supply pump 3P038 and 4P038 (1 x oper-
tem switches back. ation and 1 x stand-by), modular mounted to-
gether with pre-filter, interconnecting pipe-
Design criteria work and valves.
The system should ensure that the fuel oil purifi- Heavy fuel oil buffer tank T059, normally insu-
ers can operate 100% without shutting off due lated steam heated, located in the tank farm.
to high level in the service tank T022 or respec- When operating the plant the heavy fuel oil
tive buffer tank T059. level must lie between the minimum and
The ringmain pipe is designed so that it can feed maximum gauges of the storage tanks.
up to five engines. Heavy fuel oil daily service tank T022, nor-
The supply pump P018 is designed at 1.6 x con- mally insulated steam heated, located in the
sumption of one engine x 5 engines (maximum). tank farm.
The number of DN80 connections installed at When operating the plant the heavy fuel oil
the unloading station is to be clarified at the con- level must lie between the minimum and
maximum gauges of the storage tanks.
0701-0401PA.fm
rated at 30bar, air cooled with automatic de- for engine start/stop attempt................... 15bar
Maximum pressure of air receiver ........... 30bar
0701-0501PA.fm
Water quality
Checking water
Water softness.
Concentration of additives.
Water hardness.
Chloride ion content.
Periodical checks should be carried out on the
cooling water and preheating system.
Treated water may become contaminated in
service and the additive will loose some of its ef-
ficiency as a result. It is therefore necessary to
check the cooling system and the condition of
the cooling water at regular intervals.
0701-0601PA.fm
0701-0601PA.fm
0703-0101PO.fm
Figure 7-1 Equipment schedule for lube oil supply system - 55MW plant
Figure 7-2 Schematic diagram for lube oil supply system - 55MW plant
0703-0201PO.fm
Figure 7-3 Equipment schedule for water supply and treatment system - 55MW plant
Figure 7-4 Schematic diagram for water supply and treatment system - 55MW plant
0703-0301PO.fm
Figure 7-5 Equipment schedule for Diesel oil supply system - 55MW plant
Figure 7-6 Schematic diagram for Diesel oil supply system - 55MW plant
0703-0401PO.fm
Figure 7-7 Equipment schedule for heavy fuel oil supply and treatment system - 55MW plant
Figure 7-8 Schematic diagram for heavy fuel oil supply and treatment system - 55MW plant
0703-0501PO.fm
Figure 7-9 equipment schedule for start / control air supply system - 55MW plant
Figure 7-10 Schematic diagram for start / control air supply system - 55MW plant
0703-0501PO.fm
0703-0601PO.fm
Figure 7-11 Equipment schedule for engine preheating system - 55MW plant
Figure 7-12 Schematic diagram for engine preheating system - 55MW plant
0703-0601PO.fm
0704-0101PP.fm
Figure 7-13 Equipment schedule for lube oil supply system - 105MW plant
Figure 7-14 Schematic diagram for lube oil supply system - 105MW plant
0704-0201PP.fm
Figure 7-15 Equipment schedule for water supply and treatment system - 105MW plant
Figure 7-16 Schematic diagram for water supply and treatment system - 105MW plant
0704-0301PP.fm
Figure 7-17 Equipment schedule for Diesel oil supply system - 105MW plant
Figure 7-18 Schematic diagram for Diesel oil supply system - 105MW plant
0704-0401PP.fm
Figure 7-19 Equipment schedule for heavy fuel oil supply and treatment system - 105MW plant
Figure 7-20 Schematic diagram for heavy fuel oil supply and treatment system - 105MW plant
0704-0501PP.fm
Figure 7-21 Equipment schedule for start / control air supply system - 105MW plant
Figure 7-22 Schematic diagram for start / control air supply system - 105MW plant
0704-0601PP.fm
Figure 7-23 Equipment schedule for engine preheating system - 105MW plant
Figure 7-24 Schematic diagram for engine preheating system - 105MW plant
0704-0601PP.fm
Components
The main components are
- pumps,
- safety valve,
- electric motor,
- base frame
Design Criteria
Pumping set completely mounted on Frame
with oil pan, oil drain and plug.
Pipe completed, ready for operation, including:
strainer/ filter,
pressure gauges
100% power on time
Delivery head depending on the requirements.
Further informations also see Chapter 6.1.1 "Se-
lection of economic serial products and pro-
curement of accessories (electric motors,
pumps, strainer and filter, control valves, cooler/
heat exchanger)", Page 6-3 and following.
Drawings of the schematic diagram see Chap-
ter 7.2.1 "Lube oil supply system", Page 7-18,
0801-0101PA.fm
0801-0101PA.fm
Water treatment module T040 Required water quality for different purpose see
also Chapter 3 "Quality requirements", Page
Purpose 3-1.
A water processing plant convicts available wa-
ter with the necessary quality to the different cir-
cuits, e.g.:
Cooling water system
Cooling tower
Steam generator, etc...
Features
For each possible application the corresponding
preparation procedure, depending on the quality
of the available water, has to be chosen.
This differs from the simple water softening plant
with regeneration by recycling salt to the com-
plete demineralisation by reverse osmosis or ap-
propriate combinations.
Depending on the circuit, additiv dosing has to
be provided if necessary.
Components
The main parts of a water treatment plant are
depending on the requirements:
Softening
Demineralisation
Additiv dosing
Design Criteria
The essential concept of a water treatment
plant has to be determinated individually ac-
cording to the requirements, e.g.
Size of the Power plant, means consumption
of water
Water circuits (Cooling water circuits ,steam
generation, and so on)
0801-0201PA.fm
Features
The pressure increase plant consists of one or
more pump with all necessary connections, dia-
phragm expansion tank and a control unit on a
common base frame. The plant is pre- finished
for installation.
Components
The pressure increase plant mainly consist of
the following components:
Feed pump
Diaphragm type expansions tank
Control of the pump by a pressure transmitter
for manual or automatical mode
Combination of valves for mixing, filling and
draining for the engine water systems.
Design criteria
Depending on the dimensions of the power plant
one or more pressure increase plants, arranged
with one or more feed pumps, have to be ap-
plied.
Therefor please See Schematic Diagram in
Chapter 7.2.2 "Water supply and treatment sys-
tem", Page 7-20, Chapter 7.2.2 "Water supply
and treatment system", Page 7-20 and Chapter
7.3.2 "Water supply and treatment system",
Page 7-36.
ALso see Module drawings in Chapter 8.2.2
"Water supply, treatment modules and compo-
nents", Page 8-17, Chapter 8.2.2 "Water supply,
treatment modules and components", Page
8-17, Chapter 8.3.2 "Water supply, treatment
modules and components", Page 8-29.
For general description see Chapter "Centrifu-
gal pumps", Page 6-5.
0801-0201PA.fm
Supply modules MOD015 and MOD024 Chapter 8.3.3 "Diesel oil supply modules and
components", Page 8-31.
Purpose
Supply modules are used to deliever fuel oil from
and to different tanks, filter as well as to con-
sumers.
Features
Supply modules consists of two or more pump
units built up on a common steel base frame.
Components
The main components are
- pumps,
- safety valve,
- electric motor,
- base frame
Design Criteria
Pumping set completely mounted on Frame
with oil pan, oil drain and plug.
Pipe completed, ready for operation, including:
strainer/ filter,
pressure gauges
100% power on time
Delivery head depending on the requirements.
Further informations also see Chapter 6.1.1 "Se-
lection of economic serial products and pro-
curement of accessories (electric motors,
pumps, strainer and filter, control valves, cooler/
heat exchanger)", Page 6-3. Drawings of the
schematic diagrams see Chapter 7.2.3 "Diesel
oil supply system", Page 7-22, Chapter 7.2.3
"Diesel oil supply system", Page 7-22 and
Chapter 7.3.3 "Diesel oil supply system", Page
7-38 as well as module drawings see Chapter
8.2.3 "Diesel oil supply modules and compo-
0801-0301PA.fm
Purpose
Filter modules are used to refine possible impu-
rities from the fuel system (Ring main pipe).
Features
The refined fuel oil/ dirt composite is gathered in
a leakage oil tank. The mixture is carried back to
HFO- separator, where it will be recycled, by a
drainage pump. This process allows the re- use
of the fuel. (Only small quantities of diesel oil are
expected).
Components
The Filter module (Diesel oil part) consists of the
following main components:
- DO- Double- Filter FIL005
- Leak oil tank 1T006
- Drain pump 1P010
- Level- control for drain pump
Design criteria
The leakage oil tank serves as the chassis of the
module. The aforementioned components are
easy to maintain and mounted functionally on
the chassis.
By maintenance at the double filter the whole oil
content can be discharged into the leakage
tank.
Features
Supply modules consists of two or more pump
units built up on a common steel base frame.
Components
The main components are
- pumps,
- safety valve,
- electric motor,
- base frame
Design Criteria
Pumping set completely mounted on Frame
with oil pan, oil drain and plug.
Pipe completed, ready for operation, including:
strainer/ filter,
pressure gauges
100% power on time
Delivery head depending on the requirements.
Further informations also see Chapter 6.1.1 "Se-
lection of economic serial products and pro-
curement of accessories (electric motors,
pumps, strainer and filter, control valves, cooler/
heat exchanger)", Page 6-3. Drawings of the
schematic diagrams see Chapter 7.2.4 "Heavy
fuel oil supply and treatment system", Page
7-24, Chapter 7.2.4 "Heavy fuel oil supply and
0801-0401PA.fm
HFO- Filter module MOD009 8.3 "Plant-related supply modules and compo-
nents - drawings for 105MW plant", Page 8-27.
Purpose
Filter modules are used to refine possible impu-
rities from the HFO- system (Ring main pipe).
Features
The refined fuel oil/ dirt composite is gathered in
a leakage oil tank. The mixture is carried back to
HFO- separator, where it will be recycled, by a
drainage pump. This process allows the re- use
of the fuel.
Components
The Filter module (HFO- part) consists of the fol-
lowing main components:
- HFO oil automatic back flushing filter
1FIL003
- Leak oil tank 1T006
- Drain pump 1P010
- Control system for automatic filter
- Level- control for drain pump
- Heating coil
Design criteria
The leakage oil tank serves as the chassis of the
module. The aforementioned components are
easy to maintain and mounted functionally on
the chassis.
By maintenance at the automatic back flushing
filter the whole oil content can be discharged
into the leakage tank.
Purpose
To provide compressed air in adequate amount
and pressure to start a diesel engine.
Features
Air receiver vertical type on footing frame weld-
ed construction with valve head DN80 for V48/
60 engine or DN50 for V32/40 engine man hole,
drain socket on the receiver bottom including
drain valve.
Components
The air receiver consists of a welded bottle with
a special designed and calculated valve head
Design criteria
Design pressure (Safety valve set to 33 bar) op-
erating temperature at 50 C.
Surface treatment
Receiver inside and outside sandblast to DIN
55928 Part 4, Degree of purity SA 2 1/2
Paint
- Inside 1 x Celerol- Reaction- Ground
- Outside 1 x Varnish paint
Compressor module MOD022 duces wear rate extended TBO (Time between
overhaul) and easy to maintain.
Purpose Switch- on pressure 24 bar
Production of compressed air for starting and Switch- off pressure 30bar
control of diesel engines.
Automatic condensate trap
Features 100% power on time
Complete compressor units mounted on a com- Elast. bearing
mon base frame for compressor and accesso-
ries. Components completely mounted piped
and cabled with oil pan, oil drain and screw. See schematic diagrams in Chapter 7.2.5 "Start
/ control air supply system", Page 7-26, Chapter
Components 7.2.5 "Start / control air supply system", Page
Compressor is air cooled with intermediate 7-26 and Chapter 7.3.5 "Start / control air sup-
and follow up cooler ply system", Page 7-42.
Non return valve Module drawing see Chapter 8.2.5 "Start / con-
trol air supply modules and components", Page
Oil and water separator 8-23, Chapter 8.2.5 "Start / control air supply
Flexible hose for compressed air connection modules and components", Page 8-23 and
Chapter 8.3.5 "Start / control air supply modules
condensate collecting pan at the lower frame and components", Page 8-36.
set of vibration metal elements for resilient
mounting
flexible hoses between condensate dis-
charge and condensate collecting
accessories for automatic operation,
control cabinets
Selector actuator "Hand- O- Automatic"
Programming unit for cyclic condensate dis-
charge from the coolers durig operation
Electro- magnetic 2- way valves for each step
for starting relief and condensate discharge
The module with its components is suited for
diesel engine operation. The devices in the
module are arranged to ensure easy mainte-
nance and accessibility.
Design criteria
Three stage compressor air cooled, direct drive.
MAN B&W Diesel uses 3 stage compressors be-
0801-0501PA.fm
Design criteria
The unit is designed to heat up aqueous media
by means of electrical energy and to maintain
the required temperature by means of an regula-
tor. A built- in pump forces the medium through
0801-0601PA.fm
0801-0601PA.fm
Figure 8-2 Pressurising module for the water supply system (with stand- by pump)
Pressurising module
Figure 8-3 Pressurising module for the water supply system (with single- by pump)
Module weight: 31 kg
0803-0201PO.fm
Filter module
Filter module
N1 MDO inlet
10 Flushing tank 540 litres with drain pump N2 MDO outlet
20 Automatic filter N3 HFO inlet
30 Reversible with cover safeguard N4 HFO outlet
50 Control box N5 Leakage outlet
N6 Vent
Max. flow rate ........................approx. 21,3 m3/h N7 Steam inlet
N8 Condensate outlet
Weight......................................................980 kg N9 Pressure air
N10Temperature control
N11Drain
0803-0401PO.fm
Compressor
Figure 8-8 Starting air compressor - capacity 163m3/h at 30bar - 37kW, 900kg (Double compressor unit)
0803-0501PO.fm
Figure 8-10 cooling water preheating MOD004- flow rate 7,3 m3/h
7 valve
8 thermometer
Operating weight : 280 kg
Figure 8-13 Pressurising module for the water supply system (with stand- by pump)
Pressurising module
Figure 8-14 Pressurising module for the water supply system (with single- by pump)
Module weight: 31 kg
0804-0201PP.fm
Filter module
Filter module
N1 MDO inlet
10 Flushing tank 540 litres with drain pump N2 MDO outlet
20 Automatic filter N3 HFO inlet
30 Reversible with cover safeguard N4 HFO outlet
50 Control box N5 Leakage outlet
N6 Vent
N7 Steam inlet
Max. flow rate .....approx. 21,3m/h (HFO/MDO) N8 Condensate outlet
Weight ...................................................... 980kg N9 Pressure air
N10Temperature control
N11Drain
0804-0401PP.fm
Compressor
Figure 8-20 Starting air compressor - capacity 163m3/h at 30bar - 37kW, 900kg (Double compressor unit)
0804-0501PP.fm
Figure 8-22 cooling water preheating MOD004 - flow rate 7,3 m3/h
8 thermometer
Operating weight : 280 kg
0804-0601PP.fm
Features
The external exhaust gas system is, without in-
terruption, connected to the exhaust gas sys-
tem, which is installed directly downstream of
the engine.
Depending on the requirements or the fixed
c scope of supply, the external exhaust gas sys-
tem also comprises the following components:
SCR- DeNOx
Exhaust gas steam boiler
DeSOx
ESP
The exhaust gas normally leaves the plant
through a chimney see Figure 10-1, Page 10-4.
The boiler plant is dealt with under Chapter 9.3
"Heat recovery system",Page 9-11 and Chapter
10.3 "Heat recovery modules and compo-
nents",Page 10-14
Concerning DeNOx and DeSOx see Chapter 9.2
"Exhaust gas treatment system - description for
all plants",Page 9-4 and Chapter 10.2 "Exhaust
gas treatment modules and components -pho-
tographs of existing power plants",Page 10-9.
For ESP (dry electrostatic precipitator) see
Chapter 9.2.3 "Particulate Matter (PM)",Page 9-
9 and Chapter 10.2 "Exhaust gas treatment
modules and components -photographs of ex-
isting power plants",Page 10-9.
Unless other requirements such as, e.g.
- Exhaust gas resistance
- Flow noise, etc....
are the decisive factors, the particulars stated in
Chapter 6.1.5 "Exhaust gas system",Page 6-38
apply for the design of the external exhaust gas
system.
0901-0101PA.fm
NOx-emission limit (NOx calculated as NO2 ) layer module or block to reduce HC and CO
emissions depending on the sulphur content
By World Bank ........................ 2,000mg/Nm
in the fuel urea-solution.
15% 02, dry exhaust gas
Freezing point .........................approx. +5C
Or according to the regulations of the resp.
(possibly the tank is to be heated)
country
For injection pressure air or steam is re-
NOx-abatement quired.
By engine internal measures. To meet limits
more stringent than the WB, Selective Catalytic
Reduction (SCR) is necessary.
By Selective Catalytic Reduction (SCR) with
urea- or ammonia-solution as reducing agent
Note
Urea is safer to handle than ammonia.
Oxidation catalyst can be placed as the last
SCR
0902-0101PA.fm
SOx-emission limit (SOx calculated as SO2 ) essary to treat the process water and
gypsum, depending on the used process wa-
By World Bank ........................ 2,000mg/Nm
ter and fuel.
(15% O2, dry exhaust gas)
Pressure air 6bar to 8bar is required.
or
.................. 0.2t/d for power plants <50MWe Sodium hydroxide scrubbing
MWe = Electrical output at generator termi-
nals Low investment costs
Note
One DeSOx-plant can be provided up to ap-
prox. 500,000Nm/h
Per engine one exhaust gas bypass including
flaps with heated sealing air should be pro-
vided.
Limestone scrubbing
High investment costs
Low operating costs
No waste water
Gypsum must be disposed
0902-0201PA.fm
0902-0201PA.fm
Note
If a scrubber is used in generall no additional
ESP is necessary.
Further information must be obtained with a
specific contract.
0902-0301PA.fm
0902-0301PA.fm
Engine and tank farm............... approx. 850kg/h The following boiler designs are possible:
(equals 480kW) Steam boiler
Heat demand for 3 engines Self-regulating boiler with integrated evapo-
and tank farm.............................approx. 2.6to/h rator drum. This boiler has a certain self-
(equals 1470kW) cleaning effect on the exhaust gas tube side,
see picture in Chapter 10.3.1 "Exhaust gas
Experience shows that the heat output is re- boiler for steam generation", Page 10-14 and
duced by approx. 1/3 due to the development of according diagram Chapter 9.3.2 "Steam
deposits of plain tubes in exhaust gas boilers. generation system - diagram", Page 9-13 .
The deposition stabilises after approx. 6,000h.
See Figure 9-3, Page 9-12. Thermal oil boiler, see picture in Chapter
10.3.2 "Exhaust gas boiler for thermal oil sys-
MAN B&W Diesel therefore recommends to do tem", Page 10-15 and the according diagram
without extensive exhaust gas cleaning plants in Chapter 9.3.3 "Thermal oil system - dia-
and to design larger heating areas instead. gram", Page 9-15
For the above example this results in an ar- Here the surplus heat is dissipated in the LT
rangement of radiator cooler.
Option a.) For both solutions an exhaust gas bypass for the
boiler is not necessary.
2 exhaust gas boiler of 2t nominal size each
(equals 1,150kW)
0903-0101PA.fm
and
Output
0903-0101PA.fm
0903-0201PA.fm
0903-0401PA.fm
Flow noise
The flow noise is to be calculated by the follow-
ing formula for V > 10m/s:
LWA = -5 + 60 lg V + 10 lg S [db(A)]
Flow noise is defined as the sound level caused Figure 10-5 Flow noise
by a certain flow velocity of a gas in a pipe, inde-
pendent of a sound source.
1001-0101PA.fm
1 Power house
2 Exhaust gas boiler
3 Limestone scrubber
1002-0201PA.fm
1 Steam drum
2 Feed water tank
3 Gypsum silo
4 2xbypass chimney
1002-0201PA.fm
1 Tank farm
1002-0201PA.fm
1003-0201PA.fm
With regard to the electrical power part a typical Circuit breaker for internal auxiliary consum-
Diesel power plant consists of the following ers (i.e. circuit breaker 02).
equipment:
See Chapter 11.5 "Single line diagram", Page
High voltage part 11-37.
See Chapter 11.1.2 "High voltage part", Page Voltage transformers for measuring, synchro-
11-5. nisation, protection etc.
Step-up-transformer Depending of the short circuit capacity of the
medium voltage switch board the quantity of
See Chapter 11.1.3 "Step-up-transformer",
gensets which are directly connected to the
Page 11-6.
same medium voltage busbar is limited.
Medium voltage part incl. neutral earthing
Bigger Diesel power plants will consequently be
system
designed with two or more medium voltage bus-
See Chapter 11.1.4 "Medium voltage sys- bar sections which are connected with their own
tem", Page 11-11. step-up-transformers to the high voltage side.
Service-transformer Accordingly, the same physically limits are valid
for the low voltage-part.
See Chapter 11.1.5 "Service transformer",
Page 11-15. The quantity of service-transformers and conse-
quently the quantity of sections of the low volt-
Low voltage part age busbar must be increased if the limits of the
See Chapter 11.1.6 "Low voltage part", Page short circuit capacity are reached.
11-18. The requirement for separate sections of low
Alternator voltage busbars, each fed from its own service-
transformer, is also possible in Diesel power
See Chapter 11.2 "Generator / alternator", plants with only one medium voltage busbar.
Page 11-19.
In such a case it is recommendable to make a
The medium voltage part consists of the follow- separate part of the low voltage busbar for the
ing single panels: common part like black start Diesel, plant relat-
Alternator circuit breaker per genset (i.e. cir- ed common auxiliaries and other common con-
cuit breakers 1, 2 and 3). sumers. This low voltage common busbar will
be either connected to one or the other low volt-
See Chapter 11.5 "Single line diagram", Page age busbar section.
11-37.
Such a technically required subdivision needs
Export circuit breaker (i.e. circuit breakers 01 more space, more control logic, is more expen-
and 03). sive etc., but on the other hand it gives the ad-
See Chapter 11.5 "Single line diagram", Page vantage of a higher availability of the Diesel
11-37. power plant. A problem in one part can easily be
isolated from the rest of the Diesel power plant
1101-0101PA.fm
Depending on customers requests and special The wires are collected in plastic ducts or in flex-
requirements of the local authorities the electri- ible PVC pipes as connections to doors.
cal system may differ from this description.
The power wires are separated from the control
In any case the design and manufacturing of the or measuring wires as far as possible.
electrical components as well as the calculation
/ engineering of the plant system has to be car- Terminals
ried out by a qualified and potential consortial
All terminals are of "non hygroscopic" material.
partner of MAN B&W Diesel.
The terminals have a minimum rating of at least
The selection of suitable electrical components 1.5 at operating intensity. Terminals for the sec-
(switch boards, busbars, circuit breakers, trans- ondaries of voltage transformers are designed
formers, cables and so on) for each different as test terminals.
project, especially with regard to the maximum
The terminal blocks and all terminals are clearly
ambient temperature is a part of the detail engi-
marked and numbered in correspondence with
neering of MAN B&W Diesel.
the drawings of the electrical system.
Standards
Normal colour codes of the wiring
All offered material complies with the following
Black 3 phase and normal control wir-
relevant standards
ing and secondary winding of
DIN/EN, voltage transformers
VDE, Light blue Neutral
ISO, Yellow/green Earthing
IEC. Red DC-wiring 24 V+
The products and systems described in this Blue DC-wiring 24 V-
guideline manual are manufactured and market-
Brown DC-wiring 110 V+
ed using a quality assurance system based on
German standard DIN ISO 9001/EN 29001. Violet DC-wiring 110 V-
Grey Secondary wiring of current
Measuring instruments transformers
Measuring instruments are flush-mounted, nor- White Wiring for potential-free contacts.
mal frame size 96mm x 96mm, with 90 scale
deflection, accuracy class 1.5 or better.
With regard to the technical progress digital
multifunction devices are also applicable.
system.
The design of the high voltage part is specific for Service voltage [kV, Hz] (acc. to the project-
each particular project and depends on the specific definition)
number of step-up-transformers and number of
Basic impulse insulation level [kV] (acc. to the
systems of the over head line.
project-specific definition)
Standard design Rated short circuit-breaking current [kA/sec]
(acc. to the project-specific definition)
Air insulated, installed outdoors
Control voltage [V, ACUPS or DC] (acc. to the
SF6-type circuit breaker with spring-charged project-specific definition)
mechanism
Auxiliary voltage [V, ACUPS or DC] (acc. to the
Motor operated disconnector with built-on, project-specific definition)
manually operated earthing switch
Lightning arrestors
Inductive current transformers (if not already
covered from the step-up-transformers cur-
rent transformers)
Capacitor voltage transformers for measur-
ing and protection
Control, protection and metering cubicle
containing
- Protection relay(s)
- Electricity meter (accuracy: active 0,2 / re-
active 0,5)
- V-meter
- A-meter
- Hz-meter
- Power factor meter
- P-meter
- Q-meter
- Steel portal for the overhead line
Grounding material for high voltage compo-
nents
Lightning piles
11.1.3 Step-up-transformer
PDS: 70 30
Electricity is usually transported over large dis- No load voltage ratio [kV/kV] acc. to the
tances using high voltage because of economic project-specific definition
reasons.
Rated frequency, 50 or 60Hz, acc. to the
Therefore, the step-up-transformer and the high project-specific definition
voltage part might not exist in power plants with
Vector Group, YNdd, or acc. to the project-
an adjacent power consumption (e.g. industrial
specific definition
powerplant, city power station).
Tapping range on the high voltage side,
The electrical energy for export into the grid will
10% ... +10% or acc. to the project-specific
be transformed to high voltage level by means of
definition
step-up-transformer.
Tap changer motor operated, on load, or acc.
Depending of the number of gensets, the power,
to the project-specific definition
the short circuit capacity, the required availabil-
ity and other parameters the number of step-up- Method of cooling: ONAN or ONAF
transformers are to be specified. - First letter: Coolant for the winding
Under special circumstances (e.g. on a barge O = Mineral oil
because of the limited space) it is recommended - Second letter: Manner of circulation for
to use a three winding type with 2 x medium the winding
voltage windings. N = Natural circulation
The step-up-transformer will be located outside - Third letter: Coolant for cooling the out-
and near to the high voltage switchyard. side of the transformer
Because of the high current in the medium volt- A = Air
age cables to the transformer it should be - Fourth letter: Manner of circulation for
placed as near as possible to the export feeder cooling the outside of the transformer
of the medium voltage switch board. N = Natural circulation
F = Forced circulation
Description of the step-up-transformer
Temperature rise in oil / winding, 60C / 65C
Three-phase oil-immersed transformer for out- or acc. to the project-specific definition
door installation, generally designed according
Impedance voltage at ONAF output, 18% or
to IEC 76 standards, with motor operated on
acc. to the project-specific definition
load tap changer.
Accessories, fittings and material testing are ac- Accessories
ceptable according to the relevant DIN stand-
Bushings on high voltage and medium volt-
ards.
age side
Electrical and thermal data Built on current transformers on high voltage
side for metering and protection
Rated output at ONAF [MVA] acc. to the
project-specific definition Remote control for OLTC (loose supply to be
installed at a suitable location)
Rated power factor acc. to the project-spe-
1101-0301PA.fm
1 Rating and diagram plates, general plan of pipes and 29 Conservator oil sediment drain plug
valves 30 Oil sampling plugs (bottom, top)
2 Transformer lifting lugs 31 Terminal box for current transformer
3 Jacking lugs 32 Buchholz protective relay
4 Transformer haulage eyes 33 Cut-off valve for Buchholz protective relay
5 Skids 34 Oil flow operated relay for OLTC protection
6 Conservator lifting eyes 35 Cut-off valve for OLTC protective relay
7 Earthing terminal for tank 36 Magnetic oil level indicator for transformer oil
8 Potential connection 37 Magnetic oil level indicator for OLTC oil
9 High voltage bushing 38 Pressure relief device
10 Low voltage neutral bushing 39 Air vent plug
11 Low voltage bushing 40 Oil temperature indicator
12 On load tap changer 41 Manometric sensor of oil thermometer
13 Motor drive unit 42 Winding temperature indicator
14 Radiator 43 Manometric sensor of winding thermal relay of winding
15 Fan thermometer indicator (42)
16 Butterfly valve 44 Cable box
17 Conservator for oil transformer 45 Cut-off valve on pipe connection between tank and
18 Conservator for OLTC oil OLTC
19 Silicagel breather for transformer oil 46 Control cabinet
20 Silicagel breather for OLTC oil 47 Terminal marking plates
22 Handholes for lifting of core windings and cover 48 Oil outlet to oil treatment plant
23 Transformer oil filling and filtering valve 49 Oil inlet form oil treatment plant
24 Transformer oil drain and filtering valve 50 Plates for cables
25 Conservator filling and drain valve for transformer oil 51 Bushing for core earthing
26 Conservator filling and drain valve for OLTC oil 52 Bushing for core beams earthing
27 Conservator oil filling hole and plug (additional) 53 Surge arrester
28 Tank oil sediment drain plug 54 Surge counter
1101-0301PA.fm
1101-0301PA.fm
Figure 11-4 Earthing system with one star point per medium voltage system
1101-0401PA.fm
Figure 11-5 Earthing system with one star point for all medium voltage systems
For the electrical power supply of the auxiliaries Accessories, fittings and material testing are ac-
in typical MAN & BW Diesel power plants we use ceptable according to the relevant DIN stand-
only low voltage equipment. No auxiliary is so ards.
large that it has to be operated with higher volt-
age. Electrical and thermal data
Depending of the rated frequency in the relevant Rated output at ONAN [kVA] acc. to the
area MAN B&W Diesel normally uses a voltage project-specific definition
level of 230/400V, 50Hz or 277/480V, 60Hz.
Rated power factor acc. to the project-spe-
In case the voltage for lighting and other small cific definition
power equipment differs from this auxiliary volt- No load voltage ratio [kV/kV] acc. to the
age an additional small transformer is required. project-specific definition
This would be apply to the 60Hz grids with a
lighting voltage of e.g.120V. Rated frequency 50 or 60Hz acc. to the
project-specific definition
The electrical energy for the auxiliaries in a typi-
cal powerplant will be transformed to the low Vector Group, Dyn5 or acc. to the project-
voltage level by means of the service-transform- specific definition
er (station transformer). Tapping range on the high voltage side
The number of service-transformers is to be -5% ... +5% or acc. to the project-specific
specified depending of the number of gensets, definition
the required auxiliary power, the short circuit ca- Tap changer, manually operated, off load or
pacity, the required availability and other param- acc. to the project-specific definition
eters. Method of cooling, ONAN
The normal type of service-transformer will be Temperature rise in oil / winding 60C /
an outside standing oil-immersed transformer 65C or acc. to the project-specific definition
but under special circumstances (e.g. on a
barge because of the limited space) it is recom- Impedance voltage at ONAN output 6% (or
mended to use a dry type encapsulated cast acc. to the project-specific definition
resin power transformer for inside installation.
Accessories
The service-transformer will be located outside
of the powerhouse. Bushings on high voltage and low voltage
side
Because of the high current in the low voltage
cables to the low voltage subdistribution the Manual operating device for off-circuit tap-
service-transformer should be placed as near as changer
possible to the import feeder of the low voltage Double float Buchholz relay
main distribution.
Temperature sensors for protection purposes
Description of the service-transformer Dial type oil temperature indicator
Three-phase oil-immersed transformer, for out- Dial type winding temperature indicator
door installation designed in general according Magnetic oil level gauge
to IEC 76 standards, with manual operating off
1101-0501PA.fm
Silicagel breather
load tap changer.
1101-0601PA.fm
Bearings
General design
Depending on the manufacturer and the alterna-
tor size the machines will be equipped either
with antifriction or sleeve bearings.
Thermal protection
One Pt100 thermometer per bearing shall be fit-
ted to trigger high temperature alarm and to shut
down the Diesel engine in the event of excessive
high bearing temperature. MAN B&W Diesel
uses two stages of over temperature signals,
one for warning and the other for trip of the
1102-0201PA.fm
genset.
All secondary current transformer loops must be The alternator has a shaft mounted fan inside so
short circuited before the first run of the alterna- that normally no additional forced air stream is
tor. required.
The standard cooling method according to
Location of the electrical terminal boxes IEC34-6 is IC0A1 (open circuit air cooling) with
1102-0301PA.fm
In case of difficult surrounding conditions ing tolerances must not be exceeded prior to
(dusty, sandy and/or aggressive atmosphere) it closing the circuit breaker:
is also possible to have water cooled alternators
Voltage tolerance 5% of UN
with a cooling method according to IEC34-6 of
IC8A1W7. Frequency tolerance 2% of fN
Water cooled alternators will additionally be Phase angle tolerance 10 (electrical).
equipped with leakage detectors. Please note that these figures are only guiding
The flanges of the cooling water system and the values. In weak networks it could be required to
electrical terminal boxes will be on the opposite increase these tolerances to ensure that the
sides, that means the flanges will be according synchronisation will be possible within an ac-
to MAN B&W Diesel standard design on the right ceptable time.
side. In order to prevent synchronization errors, for
example due to the actions of unqualified oper-
Excitation system and voltage regulator ating personnel, it is advisable to install a syn-
The electrical power for the excitation system is chronizing checking relay in the switchgear
supplied by the alternator itself and the initial ex- which releases the circuit breaker only after the
citation at start-up realized by means of a per- prescribed synchronizing conditions have been
manent magnet in the exciter or by remanence. met. After paralleling the active and reactive
It is no external power source required for the load distribution must be balanced.
excitation (except the control voltage).
Stationary operation / load distribution
The excitation power at short circuit is supplied
by the alternators built in current transformers Active load sharing is achieved by the Diesel en-
through rectifier. gines speed governor. Reactive load sharing is
made by the generators voltage regulator.
In general a digital automatic voltage regulator is
used, which is located outside of the alternator. The following methods of reactive load distribu-
tion may be used:
The automatic voltage regulator is either in-
stalled in the panel of the electrical control sys- Voltage Droop
tem or in a small separate cubicle near the
alternator. The terminal voltage is lowered relative to the re-
active current. The identical voltage droop is re-
Parallel operation quired for maintaining the reactive load
distribution in proportion to the output.
Conditions The voltage droops cos relationship ensures
The generators to be connected to the mains or that in parallel operation with the mains and
operated in parallel must comply with the syn- when the mains voltage fluctuates any apparent
chronization conditions, i.e. they must be identi- change in output is kept to a minimum. This
cal with regard to the following criteria: method can be used up to mains voltage fluctu-
ation of 2%.
Voltage
The voltage droop at nominal current is as fol-
Frequency lows:
Phase sequence / direction of rotation 0% at cos = 1
Phase angle. 1.3% at cos = 0,9
1102-0301PA.fm
Proven experience results in a factory setting for eration that, if voltage and frequency deviate
ensuring stable operation of 3% at nominal cur- from the nominal values, the temperature at
rent and cos = 0.1. For alignment purposes constant nominal power will increase. This re-
with different makes, the droop shall be adjust- duces the service life of the winding and, as a re-
able infinitely from 0% - 6% of the nominal volt- sult, that of the overall machine. Voltage
age. increases cause temperature rises in the iron of
the main machine which will be transmitted to
Power Factor Regulation the winding. Drop in voltage cause a rising cur-
rent and, as a result, the winding temperature in-
This method is used for parallel operation with
creases. Since the service life of the winding is
the mains when heavy voltage fluctuations oc-
always compromised if the temperature in the
cur, or in co-generation plants when they have
relevant temperature class is exceeded, it is ad-
to be operated with a defined cos to the
visable to prevent operation at the extreme lim-
mains. A cos regulator energises the voltage
its for longer periods. This will be ensured if the
regulator in order to maintain the pre-set power
generator is built and operated in accordance
factor, i.e. the generator voltage is automatically
with the operating data known during project
adjusted to the mains voltage.
stage.
Mains Parallel Operation
Oscillations
Since in the majority of cases the mains has a
Periodic fluctuations in active and reactive load
much higher short-circuit capacity than the gen-
are caused by the irregular torque variations of
erators, the number of units running in parallel is
internal combustion engines. In order to attenu-
irrelevant so that no significant influence is ex-
ate these fluctuations in parallel operation, a
erted. As a result, almost all voltage fluctuations
damper cage shall be installed in the generator
are determined by the mains.
as standard.
In the event of mains voltage fluctuations of U
2% the voltage droop as described above can
be used.
In the event of mains voltage fluctuations of U
2% a cos regulator is used which automati-
cally adjusts the generator voltage to the mains
voltage by influencing the exciter voltage. This
ensures that the pre-set power factor remains
constant in the event of mains voltage fluctua-
tions or if the generator is subject to various
loads.
If a certain power factor is required at the mains
interface point, the current transformer effecting
the cos regulator must be located at this point,
It is advisable in this case to install an exciter
current limiter in order to prevent the exciter cir-
cuit from being overloaded. It limits the exciter
current to the value of the nominal power rating
at cos =0,8.
1102-0301PA.fm
1102-0301PA.fm
Design criteria
As far as possible, the plant control and monitor-
ing system is designed for centralised operation
of the plant.
Centralised operation is realised through a high
degree of automation on all control levels. How-
ever, local start is required for some auxiliary
systems for operational reasons only.
High degree of automation, simplicity of the
control and monitoring architecture and reliabil-
ity of all components allow safe and economic
running of the plant with a minimum of staff.
If desired, the power plant can also be operated
manually by turning the selector switch.
Architecture
The overall plant control and monitoring system
comprises three different levels of automation.
1103-0101PA.fm
Common control and monitoring system Single line diagram with circuit breaker posi-
tion indication and additional electrical meas-
The common control and monitoring system
uring values
starts and stops the generating sets and the
common mechanical power plant systems. It Long term trend monitoring and intelligent di-
controls all common mechanical power plant agnosis functions can be implemented.
systems which do not have individual local con-
trol functions. Operation parameters
The common control and monitoring system
synchronises the power plant with the grid, dis- Mechanical
connects the plant from the grid in case of grid Engine speed
failure and controls and protects all common
electrical systems such as feeders, transform- Turbocharger speed-; exhaust gas tempera-
ers, etc. tures after cylinder, before and after turbo-
charger
The main control & protection features of the
Common control and monitoring system are: Main bearing temperatures
System for network disconnection by moni- Splash oil temperatures from the crankshaft
toring of grid frequency and grid voltage (grid Lube oil temperature before engine
parallel operation only)
Lube oil pressure before engine.
Plant active and reactive load control
Lube oil pressure before turbocharge
Automatic synchronising for the mains feeder
Lube oil temperature after turbocharger
Circuit breaker control and monitoring (low
Cooling water temperatures before and after
voltage, over current, short circuit, earth fault)
engine
Load shedding
Cooling water pressure before engine
Load sharing on the generating sets
Fuel oil pressure before engine
The plant operating panel allows direct influence
Fuel oil temperature before engine
on all plant equipment
Charge air temperature before and after com-
The graphic display of the plant operating panel
pressor
visualises the present operation status of the
generating sets and the complete plant. Charge air temperature after charge air cool-
er
The following system pictures can be displayed
(example): Charge air pressure before cylinder
Engine with essential measuring value Starting air pressure
Alternator with main electrical measuring val- Control air pressure
ues
Lube oil system, fuel oil system, cooling wa-
ter systems, intake air system, exhaust gas
1103-0201PA.fm
er high
11.3.3 Engine
PDS: 10 30, 80 10
Engine management system responds prior to the engine alarm system. Thus
CoCoEDS allows the user to take the necessary
Each engine is equipped with an engine man-
countermeasures long before any serious de-
agement system, located near the engine, inside
fects or failures appear. In this way, unneces-
the powerhouse. The system includes modules
sary stoppages of the engines can be avoided,
to realise and control functions related to oper-
maintenance work reduced and availability of
ation. These modules are individual compo-
the plant increased.
nents, which offer the advantage that they can
be optimized, maintained and exchanged inde- To achieve these unique features, CoCoEDS re-
pendently of each other. lies on performance graphs which are generated
by MAN B&W Diesel engineers for each single
The basic functions of the system are:
engine at the place of installation. Thus, the ac-
Cylinder lubrication. tual operating conditions at site are taken into
Control of injection timing. accout. This would not be possible with per-
formance graphs created on the test bed only.
Load control.
As CoCoEDS can be freely configured and ex-
tended, it is also possible to include further plant
Engine diagnostic system
auxiliaries in its functions.
The Computer Controlled Surveillance - Engine
Since its introduction, CoCoEDS has not only
Diagnostic System (CoCoEDS) is a personal
been installed in more than 50 stationary power
computer-based system for the supervision of
plants world-wide, further it monitors and con-
plant operation, which allows the user far more
trols our own testbeds at our works in Augsburg
than simply the visualisation of current operating
without the use of any additional systems.
data in various forms (monitoring function).
In fact, we rely on computer CoCoEDS as our
The trend function of CoCoEDS allows the user
round-the-clock engineer on our testbeds. The
to study all relevant engine operating data, in
computer controlled surveillance - engine diag-
short term trend mode, i.e. at very short inter-
nostic system can also be your round-the-clock
vals, over a period of 2 weeks, and in long term
MAN B&W Diesel service engineer in your power
trend mode, i.e. at longer intervals, over several
plant.
years, and thus to recognise developments and
changes of operating values long before they In addition to CoCoEDS, MAN B&W Diesel op-
have an effect on the plant operation. tionally offers software for
Based on current readings taken during opera- Computer Controlled Surveillance - Mainte-
tion of the plant, the diagnosis function provides nance Planning System (CoCoMPS)
the user with a clear analysis of defects and fail-
Computer Controlled Surveillance - Spare
ures, a list of symptoms that lead to this conclu-
Part Catalogue (CoCoSPC)
sion (operating figures that deviate from the
reference figures) and a list of remedial meas- Computer Controlled Surveillance - Spare
ures to be taken. Part Ordering Software (CoCoSPO)
CoCoEDS, with its functions monitoring, trend
and diagnosis, does not replace the engine
alarm system. It is in fact subordinate to the en-
1103-0301PA.fm
In many projects it seems to become quite usual The following items shall be used as a basis for
that MAN B&W Diesel is not responsible for the technical discussion between MAN B&W Diesel
complete turnkey power plant. The scope of and possible suppliers for engine management
supply only consists of main components (e.g. system / genset management system:
Diesel engine, alternator, auxiliaries, etc.) which
The Common Control System as well as the
will be delivered to various contractors.
Plant Control System shall be realized by the
Although the contractor might be responsible contractor.
for the overall function of the power plant it is of
It shall cover all items that are not directly re-
greatest interest to MAN B&W Diesel that Diesel
lated to the Diesel engine (for engine man-
engine and alternator are protected in the best
agement system) or the genset (for genset
possible manner without depending on the con-
management system).
tractors experience and knowledge. Therefore,
MAN B&W Diesel will not deliver Diesel engine We recommend that engine management
and alternator without MAN B&W Diesel stand- system / genset management system panel
ard control panels. and engine MCC-board shall be located ad-
jacent to the genset.
Two alternatives shall be covered by the new
control concept: The PLC concept shall be based on usual
components (e.g. SIEMENS S7 or ABB) to
Engine Management System
get the best acceptance from individual con-
MAN B&W Diesel is supplier of the Diesel en- tractors.
gine and accessories only. The control sys-
Engine management system / genset man-
tem will entirely cover Diesel engine and
agement system panel shall be designed acc.
engine related auxiliaries. It shall also include
to the local operation level / philosophy, e.g.
the MCC-board for engine auxiliaries to sim-
detailed indication of all measuring values is
plify communication and layout during engi-
not required.
neering.
Local operation shall be limited for mainte-
Genset Management System
nance purposes only, e.g. no-load test, indi-
MAN B&W Diesel is supplier of the alternator cation of most important engine values on a
also. In addition to engine management sys- display.
tem the genset management system control
The contractor must provide a genset opera-
system shall also cover the alternator and the
tion / visualization panel to be located in the
genset circuit breaker incl. all necessary pro-
control room. This allows the contractor to
tection relays and synchronizing unit / check
follow his own design / layout criterias in the
synch. relay (for the alternator circuit break-
control room which will not be effected by the
er).
future MAN B&W Diesel concept.
Our solution is to use the engine management
For genset management system the follow-
system as basic module which can be extended
ing alternator protection relays shall be used:
(into genset management system) by an addi-
tional alternator module if necessary. - For differential protection
This modular concept can be used for turnkey - For overall protection.
1104-0101PA.fm
1104-0101PA.fm
1104-0101PA.fm
Figure 11-12 Division of Works for Engine Management System / Genset Management System
1104-0101PA.fm
1106-0201PA.fm
1106-0401PA.fm
1106-0501PA.fm
1106-0601PA.fm
1106-0601PA.fm
1106-0701PA.fm
1107-0101PA.fm
The earthing system has to be designed, beside connection points have to be provided on the in-
other requirements, according to the short cir- side walls around the power house at a height of
cuit capacity of the network and valid local reg- approx. 700mm above the floor. These connec-
ulations. tion points will later be connected to the equipo-
tential bus bar which is part of the inside
Responsible for the earthing system are
earthing system.
Civil contractor
Electrical contractor Outside earthing
A complete earthing system consists of MAN B&W Diesel requests an outside earthing.
Foundation earthing (design, supply and in- For buildings, standing tanks in the tankfarm
stallation usually by civil contractor) grounding conductors with suitable connectors
forming a complete ring - earthing loop - have to
Outside earthing (design, supply and installa- be provided. For these earthing loops, it is nec-
tion usually by civil contractor) essary to have a nude copper cable with a
Inside earthing (design, supply and installa- cross-section that depends upon the value of
tion or supervision usually by electrical con- failure current and clearing time. It is also possi-
tractor) ble to use two parallel cables each with half this
cross-section. The earthing loop should be laid
Lightning protection connected to the earth- at a distance of at least 1m outside the building
ing system (design, supply and installation and the tank line at least 1m below the surface.
usually by civil contractor)
In order to achieve an acceptable low grounding
In case of order, MAN B&W Diesel will submit a resistance, deep-earthing rods of sufficient
final documentation. length should be connected to the outside
earthing loops according to the specific ground-
Foundation earthing ing resistivity of the soil.
MAN B&W Diesel requests a foundation earth- Natural earthing rods, as e.g.
ing.
reinforcement steel in piles and foundations
In order to achieve low resistance, it is highly
recommended to install a foundation earthing pipe lines
system which consists of hot-dipped galvanised steel parts of buildings
band steel or round steel of at least 120mm.
have to be used and connected to the earthing
Galvanised steel each with connectors creating loops.
a concrete-embedded grid with good contact-
ing nodes has to be laid in the concrete of The earthing loops should be connected togeth-
er, to the foundation earthing and to the inside
Piles earthing. Further, all metal structures such as
Genset foundations exhaust gas stacks, radiator cooling plant, sub-
station, transformers, fence, etc. should be con-
Building foundations
1108-0101PA.fm
Lightning protection
The lightning protection system has to protect
buildings, persons etc. against lightning effects
and will be designed according to the local reg-
ulations and / or the DIN/VDE-standards, espe-
cially if it will be supplied from Germany.
The lightning protection system consists of
Collecting device
Down lead
Grounding
Collection devices will be mounted on several
1108-0101PA.fm
Figure 11-18 Steel reinforcing bars earthing Figure 11-20 Sealed typical connection bar
Figure 11-19 Earthing simple sabot Figure 11-21 Typical civil work for a checking chamber
1108-0101PA.fm
Figure 11-22 Principle of connection in checking chamber Figure 11-24 Protection of floors crossing on electr. rooms
Figure 11-23 Earthing connection for electronic mass Figure 11-25 Wall crossing
1108-0101PA.fm
Figure 11-26 Earthing of low voltage motor frame Figure 11-28 Lightning earthing connection to crows foot
2) Support tube
Figure 11-31 Cable run down or rising principle on an
3) Way for lightening
equipment
4) U- shaped steel as support for smoke tube welded with
support tube
5) Compensation of potential by welding
6) Brass band as connection between upper and lower part
7) loop for earthing
No additional lightening poles are necessary
1108-0101PA.fm
1) Smoke tube
11.8.2 Protection
PDS: 210 60 90
Protection relays are of fixed mounted type, mi- Alternator basic protections
cro processor controlled with switches (soft-
24 overfluxing
ware or hardware) for value selection of actual
settings and trippings. 27 under voltage
The protection relays can be installed in the me- 32 Pactive reverse power
dium voltage and low voltage switchboards as 40 loss of excitation
well as in the electrical control panels.
46 neg. phase sequence
Our standard design for Diesel power plants
does not include a special panel for the limited 50 instantaneous overcurrent
purpose of protection because these functions 51 time overcurrent
can easily be included in other panels.
50 Ninstantaneous earth fault overcurrent
The following types of protection will be realized
in a typical Diesel power plant. 51 Nground fault time overcurrent
59 overvoltage
Protections on the medium voltage side
64 ground detector
Alternator protections 81 frequency
Overcurrent
Backup protections
Overload
87 differential protection
Negative phase sequence
50 time overcurrent
Zero sequence fault (current or voltage with
directionality functions) 51 time overcurrent
Protections of the busbar connected to the grid Protections of the outgoing line
These protections protect the power plant by Overcurrent
isolating it from the grid during faults from the
Overload
grid which can not be controlled and mastered
by the dedicated protections and the dispatch- Restricted earth fault with high impedance
ing: differential protection (line of 50 to 70m),
Minimum frequency or
Maximum frequency - Longitudinal differential (line of 50 to 70m),
Minimum voltage or
Maximum voltage - Pilot wire differential protection (line of 100
to 1000m),
Detection of zero sequence voltage on the
busbar. or
Protection against ferro resonance to avoid - Distance protection (line of more than
overheating and destruction of voltage trans- 1000m),
formers connected to a busbar operating at
no load or slightly loaded. Protections on the low voltage side
Protections of step up transformer Protections of black start units and service trans-
Overcurrent formers.
Purpose and definitions The touch voltage is therefore still kept down to
a safe value.
Dangerous touch / step voltages must be pre-
vented from occurring or persisting in the event No step voltage evaluation is required for low
of a fault phase / earth. voltage system.
Touch voltage UB is the part of the earthing volt-
age that a person can bridge, whereat the cur- 13.8kV system as a typical
rent flows over the human body from hand to Touch voltage is the potential difference which
foot (horizontal distance from the touched part occurs between hand and foot of a person who
approx. 1m) or from hand to hand. touches an earthed structure during a fault.
Step voltage US is the part of the earthing volt- Step voltage is the potential difference which
age that a person can bridge with a step of 1m could be picked off between the feet of a person
length, whereat the current flows over the hu- standing on the soil during a fault.
man body from foot to foot.
The tolerable touch and step voltages depend of
In contrast to the IEEE, the DIN VDE 0141 does surface soil resistivity, duration of shock current,
not give limit values for the step voltage. body resistance etc.
According to IEEE a rough simple evaluation is
480V system as a typical
given by
For low voltage system the limit values for touch
Tolerable touch voltage (body resistance =
voltages are
1000)
50V A.C.
( 1000V + 1.5c s s ) 0.157
120V D.C. ET = -----------------------------------------------------------------------------
tol
ts
In the T.N.C. system, in the event of an earth
fault on a phase conductor, the potential of the ETtol Tolerable touch voltage [V]
P.E.N. and the exposed conductive parts con- s Soil resistivity, here 100m
nected to it, relative to "0" voltage "far earth" is cs Correction factor for surface resistivity, here 1
generated according to the following formula. ts Duration of shock current
RB
U B = U 0 --------------------- Tolerable step voltage.
R +R E B
( 1000V + 6c s s ) 0.157
U0 System voltage to earth, here 277V ES = -----------------------------------------------------------------------
RE Resistance of earth fault
tol
ts
RB Earthing resistance, here = 0.9
EStol Tolerable step voltage [V]
s Soil resistivity, here 100m
On the assumption, based on experience, that cs Correction factor for surface resistivity, here 1
the resistance to earth RE at the fault location ts Duration of shock current
will be at least 7, the touch voltage UB is
1108-0301PA.fm
1
U B = 277V ---------------------------- 35V 50V
7 + 0.9
1
U B = 277V ---------------------------- 35V 50V
7 + 0.9
is 571V.
The tolerable step voltage is 795V.
The earthing voltage UE in this case is
U E = w r ( I K1 I N ) Z E
1108-0301PA.fm
1108-0301PA.fm
The average illumination levels will be according Outdoor operation areas..................... 150lux
to applicable recommendations. The illumination level of outdoor lighting will be
The average illumination levels will be at least: measured at the surface.
1109-0101PA.fm
Drawings and documentation will be issued to Item designation acc. to DIN 40719-2
the following standards: (IEC750)
DIN/EN Graphical symbols of diagrams acc. to DIN
40900-1.12 (IEC 617-112)
VDE
ISO
IEC
Most drawings of the electrical equipment will
be realized in DIN A4 size and in English lan-
guage. Larger formats are only required for
some special drawings such as the complete
detailed single line diagram.
Thanks to the standardised designation system
and the cross references orientation in the draw-
ings is easy.
The complete set of electrical drawings consists
of the following:
Electrical circuit drawings
Terminal diagrams
Single line diagram
Cable list
Equipment list
Layout and main dimension drawings of the
panels
Please note that parts of these documents may
be prepared by different sub-suppliers.
Therefore the uniformity could be more or less
liberal.
In addition to the project related tailor-made
drawings the complete documentation will con-
tain all required manuals, spare part lists, me-
chanical drawings, data sheets etc. of the
supplied modules and components.
1110-0101PA.fm
Purpose Regulations
The tank farm serves as
Restrictions
storage of inflammable liquids that are nec-
essary to operate the power plant (lube oil, The following tank farm particulars are not com-
Diesel oil, heavy oil), plete and serve only as general guidelines. The
regulations of the legislator or local authorities at
intermediate storage of sludge and waste oil the tank farm site are binding.
that arise during operation of the power plant.
Diesel plants supplied directly from a refinery or
through a pipeline are not considered in this
Design
Project Guide.
The tank farm consists of tanks of defined de-
There are no uniform rules regarding tank farms,
sign, number and size on a specially prepared
except that fuels of different grades must always
storage area (sump).
be stored in separate tanks.
The tanks are to be planned and built according
to international and / or national standards and Location of the tank farm
regulations. Usually, the storage area has a non-
leakage floor and a surrounding wall to avoid in- The location of the tank farm on the power plant
fluences on the environment during leakages. grounds depends on the:
Figure 12-1, Page 12-5, shows the typical de- tank design
sign of a vertical tank with ring foundation. The access (road, railway, waterway)
tank is inside a sump. The sump includes
terrain
Oil-tight floor,
location of adjacent buildings
Surrounding wall,
fire extinguishing facilities
Rain water collecting pit,
official regulations.
Waste oil collecting pit,
Separate drainage for water and oil. Tank size, foundation and heating
The waste is to be disposed of according to in- The tanks are installed over ground. Tanks up to
ternational and national regulations valid at the a size of 100m are usually installed vertically.
tank farm site. Depending on their size, they are delivered to
the site fully or partly assembled. Tanks exceed-
Static calculations are necessary for ing 100m content are generally installed verti-
Each tank and tank foundation, and cally. They are always assembled on site.
Each tank sump and its walls (liquid pressure The required tank size (content) depends on
of filled sump). consumption, fuel supply sources, size of the
premises and, partly, on safety regulations.
Please refer to Chapter 7 "Plant-related supply
systems", Page 7-1.
1201-0101PA.fm
Example:
First tank
Contents: III A liquid
Diameter: 8m
Second tank
Contents: III A liquid
Diameter: 12m
Distance between both tanks according to
the formula: at least 4m.
1201-0101PA.fm
Series of photo-
graphs showing
typical process of
how to built up a
vertical storage
tank including ring
foundation.
1201-0101PA.fm
1201-0101PA.fm
TANKFARM LEGEND
A) 2 x 2435 m3 HFO-STORAGE (15 DAYS)
B) 1 x 310 m3 HFO- TREATED/SERVICE
C) 1 x 400 m3 MDO- STORAGE/SERVICE
D) 2 x 20 m3 SLUDGE
E) 1 x 65 m3 LUBE OIL STORAGE
F) 1 x 30 m3 LUBE OIL MAINTENANCE
1203-0101PO.fm
1203-0101PO.fm
TANKFARMLEGEND
A) 2 x 4475 m3 HFO- STORAGE (15DAYS)
B) 1 x 650 m3 HFO - TREATED/SERVICE
C) 1 x 650 m3 MDO- STORAGE/SERVICE
D) 2 x 20 m3 SLUDGE
E) 1 x 100 m3 LUBE OIL STORAGE
1204-0101PP.fm
1204-0101PP.fm
Components
Main components
The work air system consists of the following
main components:
Electric motor driven air compressor C003,
rated at 10bar, single stage, air cooled.
Working air receiver T036 for storing the
compressed air.
Pressure reducer PCV002 to reduce the air
pressure from 10bar down to 7bar,
1301-0101PA.fm
1301-0101PA.fm
control room.
landing valves mounted to connect the hoses
to the pipe system.
Hose cabinets which contain two hoses of If pressure loss is caused by the withdrawn wa-
30m and a branch pipe each. ter, the fire fighting pump starts and an alarm is
sent to the fire detection controller.
several cabinets contain an inductor and
foam concentrate.
Foam cabinets that are mounted to the wall
contain a landing valve, a hose, an inductor,
a medium foam nozzle and foam concentrate
Mobile foam carts to utilise if foam is needed
at a landing valve where no inductor and
foam concentrate is stored.
Dry chemical extinguishers and CO2- extin-
guishers to fight fire that are small or that are
in areas where extinguishing with water is not
allowed.
Pipe system, laid around entire area.
tinuous operation.
1301-0103PA.fm
Purpose not been reached the oil water mixture is re- cir-
culated automatically this until the correct level
Prior to discharge, the collected contaminated
is obtained.
power plant process water quality has to be in
accordance with the local standards and/or oth-
er applicable international standards. Chemical treatment
The contaminated water treatment system has After one pre- water treatment by means of the
to be designed from case to case in order to aforementioned systems the remaining contam-
meet the required discharge standards. ination, i.e. zinc, copper, etc. which could pre-
vent the power plant operator from discharging
Typical water cleaning systems for diesel power it could be removed by an additional chemical
plants, but not limited to, are: treatment. The subsequent process to remove
Gravitation coalescer working principle (Coa- the water contamination comprises oil fission,
lescer) neutralization and flocculation plus an additional
filtration. After this additional process the clean
Mechanical emulsion breaker working princi- water could be discharged into the admissible
ple (Oily water separator) system.
Chemical treatment
Components
Description Oily water collecting tank
The hydrocarbon and water mixture enters the sludge collecting tank
coalescing element and flows from inside to out-
side. This is where small droplets of dispersed oily water separator
phase liquid come together, or coalesce, as the Coalescer
mixture moves through the depth of the coale-
scer medium. Chemical treatment
As oil coalesced within the unit, it rises to the top Main operating conditions
of the water surface where the oil accumulates
and builds a layer. The layer will continue to in- The contaminated process waters have to be
crease in size until a pumpout system or skim- collected in sludge and/or oily watertanks. Ac-
mer discharges it either manually or cording to the current local water cleanliness
automatically. guidelines one of the aforementioned typical
systems could be applied in order to achieve the
Oil can be removed from he unit at any time; required cleanliness level.
however, it must be removed prior exceeding
the maximum oil storage capacity rating of the The entire cleaning process could be fully auto-
unit. mated and automatically controlled.
After the required water quality is reached the
Mechanical emulsion breaker water could be discharged into admissible sys-
An oil water mixture is pumped through separa- tem.
tion profiles. Small oil droplets will transform into
larger drops by a coalescing process. The oil
drops will be collected in a separate space and
1301-0104PA.fm
1301-0104PA.fm
1302-0101PA.fm
13.2.2 Components
1302-0201PA.fm
1302-0202PA.fm
1302-0203PA.fm
1302-0204PA.fm
1304-0101PO.fm
Figure 13-6 Equipment schedule for work air system - 55MW plant
Figure 13-7 Schematic diagram for work air system - 55MW plant
1304-0101PO.fm
1304-0201PO.fm
Figure 13-8 Equpiment schedule for HFO- treatment (sludge and leakage disposal)
Figure 13-9 Schematic diagram for HFO treatment (sludge and leakage disposal)
1304-0201PO.fm
mm mm kg
Table 13-1 Separator module for 55MW plant Figure 13-11 Hoist for separator - 55MW plant
1304-0301PO.fm
1305-0101PP.fm
Figure 13-12 Equipment schedule for work air system - 105 MW pant
Figure 13-13 Schematic diagram for work air system - 105MW plant
1305-0101PP.fm
1305-0201PP.fm
Figure 13-14 Equipment schedule for HFO- treatment (sludge and leakage disposal)
Figure 13-15 Schematic diagram for HFO treatment (sludge and leakage disposal)
1305-0201PP.fm
HFO separator
mm mm kg
1305-0301PP.fm
Description
Skeleton framework and foundation
For the skeleton framework and the founda-
tion a static calculation and a stability survey
must be issued taking into consideration the
following local conditions:
- Wind velocity
- Earthquakes
- Soil bearing capacity
These calculations must also take into ac-
count the load data from the assembly layout
by MAN B&W Diesel as well as load due to
earthquakes, wind, sand and snow.
Generally, MAN B&W Diesel assumes a nec-
essary soil bearing capacity of 200 kN/m2.
1401-0101PA.fm
1401-0101PA.fm
1401-0101PA.fm
Skeleton framework
MAN B&W Diesel has developed a system which allows to configurate different sizes of power
house with certain basic modules.
The following drawings show such raster graphics for both:
- power house for engine 32/40 as well as for
- Power house for engine 48/60
1401-0101PA.fm
1401-0101PA.fm
Item plans
Furtheron these raster- modules have been calculated.
The results (beam size) are given in a so called item- plan, which also shows the necessary founda-
tion size. This can be seen on the following figures.
1401-0101PA.fm
Figure 14-14 Item plan of power house for engine 14V32/40 (cross- section)
1401-0101PA.fm
Figure 14-16 Itemplan of power house for engine 14V32/40 (longitudinal section)
Figure 14-17 Item plan power house for engine 14V32/40 (Ground floor with foundation measurement)
1401-0101PA.fm
Figure 14-18 Item plan of power house for engine 18V48/60 (cross- section)
/
1401-0101PA.fm
1401-0101PA.fm
Figure 14-20 Itemplan of power house for engine 18V48/60 (longitudinal section)
Figure 14-21 Item plan power house for engine 18V48/60 (Ground floor with foundation measurement)
1401-0101PA.fm
1401-0101PA.fm
1401-0101PA.fm
Purpose
The heat loss is dissipated from the power
house by forced ventilation to achieve tolerable
room temperatures for the personal operating
and maintaining the power plant.
Design
The direction of air flow must be from the
generator to the engine. This precludes the
possibility of generator windings being fouled
by oil.
The exhaust air opening must be arranged
and designed in such a way, that the heated
air can freely escape even during windy con-
ditions.
The pressure difference between the atmos-
phere outside and inside the power house
should not exceed 5mm W.C., having in mind
the force required to open the power house
gates.
The air flow of the ventiation units in the pow-
er house should pass the engines symmetri-
cally, see Figure 14-3, Page 14-31.
It should be possible to reduce the air flow at
low ambient temperatures to avoid strong
cooling in the power house. This may be
achieved by two- step ventilators with star-
triangle- control or by switching off single
ventilators. The symmetrical air flow to the
engines must be maintained.
The control cabinets in the power house must
have, at least an own ventilation with filter
pads in order to exceed the allowed operat-
ing temperature. At higher temperatures a
faultless operation of the electrical controls is
not guaranteed.
1401-0201PA.fm
Figure 14-3 Air flow in power house - sectional view - example for 55MW power plant
1401-0201PA.fm
Figure 14-4 Air flow in power house - top view - example for 55 MW power plant
100 geno
Qgeno x Peng [kW]
100
Example:
Input data
Engine ...........................................18V 48/60
Ambient temperature .............................35C
Installation height............73m above sea level
Specific air weight 73m above sea level and ambient air temperatur kg/m3 1.136
Heat to be dissipated
Minimum required volumetric air flow rate per engine V m3/h 220,055
cp = 1,01 kJ/kgK
1401-0201PA.fm
Normal lifting.....................................4 m/min The delivery of the cranes usually includes the
power supply as contact line, preferably on the
Travelling: cross travel speed side of the power house that is turned away from
With load...........................................5 m/min the exhaust duct, with
1401-0301PA.fm
Figure 14-9 Typical foundation for genset and maintenance platform with outline drawing - engine V48/60
1401-0402PD.fm
1401-0402PD.fm
Air renewal rate referred to room volume - Table of air quantities per separator
guide values
renewal rate
Size of separator Air quantity
[times/h]
throughput [m3/h] [m3/h]
For small, closed separator rooms 30 - 50
approx. 1.1 - 1.7 30
For large separator rooms 15 - 20
approx 1.8 - 4.5 100
For niches within engine room 50 - 70
approx. 3.0 - 10.0 150
Table 14-5 Air renewal rate - guide values
Table 14-6 Table of air quantities per separator
1401-0501PA.fm
Figure 14-15 Inside view of pump house and treatment plant of a executed power plant
1401-0501PA.fm
Figure 14-16 Piping between pump house, tank farm and power house of an executed power plant
1401-0501PA.fm
1401-0601PA.fm
1401-0701PA.fm
Peak load
Company name
Stand- by (back- up
Type of activity only)
Project- name Stand-by/ peak load
(back-up only)
Contact person
Telephone- no.
3. Required service from MAN B&W Diesel Engine speed prefer- No Yes rpm
ence
Remarks:
8. Voltage levels
__________________________________________
__________________________________________
High voltage level/ mains kV
__________________________________________
voltage
__________________________________________
Medium voltage level/ kV __________________________________________
alternator voltage
__________________________________________
Low voltage level/ auxil- V
iary voltage
1501-0101PA.fm
11. Maximum operation hours per genset 13. Type of liquid fuel
Crude oil
Radiator X
Cooling tower
Yes, see
Available water quan- m3/h
tity for cooling tower
River water
Viscosity cSt
>/= C
Density kg/dm3
Inlet water temper- C
atur </= C Crude oil flash point c
>/= C
Inlet water temper- C Supply pressure (over- barg
atur </= C pressure)
Supply temperature C
Quantity m3/h
Lower calorific value kJ/kg
Return water temper- >/= %
ature % Methane number
</= %
or
According to world Gas analysis No
bank standard dT= 3K
Yes, see
1501-0101PA.fm
HFO storage capacity days full operation Low temperature (LT) No Yes
required, Usable
LFO storage capacity days full operation temp.range: 25 ... 31C
Power demand MW MW
Power demand MW MW
HC mg/Nm3
ature
Engine(s)
Alternator(s)
Tank farm
Sanitary installations
1501-0101PA.fm
Electrical system
Please indicate number of components (if re-
quired)
High voltage-switchgear
Step- up transformer
MV- switchgear
Station transormer(s)
Tank farm
Communication/ telephone
system
Powerhouse construction
Administration building
Guard house
Tank farm
DeSOx- plant
21. Services by MAN B&W Diesel 22. Pricing/ calculation factor for quotation
Delivery to Additions
Commissions + %
European North seaport FOB
Leadership fee for con- + %
Nearest dest. harbour, CIF sortial partner
see "Site location", page
15-3 Bank fees + %
Insurance fees + %
See "Site location", page CIP
15-3 Additional/ special costs + %
(SEK)
See "Site location", page DDU
+ %
15-3
+ %
Site service
Remarks:
Signature of sales manager/ date:
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
1501-0101PA.fm
1501-0101PA.fm
1501-0101PA.fm
MDP- Manager for bills of material Drawings of modules and components (mod-
els)
1502-0101PA.fm
1502-0101PA.fm
1503-0101PA.fm
1503-0101PA.fm
1503-0101PA.fm
Piping classification
1504-0101PA.fm
Piping classification
1504-0101PA.fm
Piping classification
1504-0101PA.fm
1504-0101PA.fm
1505-0201PA.fm
1505-0101PA.fm
1505-0301PA.fm
The next figure shows the maintenance platform ternator and at the front, the arrangement of the
of the engine with starting air bottle, air inlet of lube oil purifier.
the power house ventilation, control box for al-
Figure 15-6 Main lube oil pump with lube oil module
1506-0101PA.fm
1506-0101PA.fm
1506-0101PA.fm
Figure 15-9 Noise map estimation for a 55MW power plant with 3 x engine 18V 48/60
1507-0101PA.fm
Standard design with el. annex at the long side of the power house
No. of engines 3
Center of coordinates system (X = 0, Y = 0) wall of mech. annex and centerline of DG set No.2
No. of Cylinders 18
1507-0101PA.fm
15.8 Miscellaneous
Weights
Stated weights have a tolerance of +/- 5% and
do not include packing or water and oil fillings of
the plant
1508-0101PA.fm
1508-0101PA.fm
16.1 Symbols
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1601-0101PA.fm
1602-0101PA.fm
1602-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
1603-0101PA.fm
16.4 Abbreviations
MGO Marine Gas oil
LT Low temperature
1604-0101PA.fm
1605-0101PA.fm
1605-0101PA.fm
16.6 Flow rate and velocity diagram for liquids, gases and
vapours
The guide values for designing the nominal
width of systems are definedin the following fig-
ure.
1606-0101PA.fm
1606-0101PA.fm
gram)
m fv
1607-0101PA.fm
1608-0101PA.fm
1608-0101PA.fm
1608-0101PA.fm
1608-0101PA.fm
Index
Numerics Cooler
Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2-circuit radiator cooling system Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Engine 48/60 - related system . . . . . . . . . . . . . . . 5-8 Cooling tower cooling system
Engine 48/60 - related system . . . . . . . . . . . . . . . 5-20
A Cooling tower cooling system (forced- air- cooled) . . 6-30
Cooling tower module, component
Acceleration times . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Engine 48/60 - related module, component . . . . 6-59
Accessories procurement. . . . . . . . . . . . . . . . . . . . . . . 6-3
Cooling water
Adjustment Checking of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Output power . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Cleaning of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Air intake filter For engine, quality requirement . . . . . . . . . . . . . . 3-11
Deposition degree . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Air intake protection Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Weather protection grid. . . . . . . . . . . . . . . . . . . . 6-31
Air vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 D
C Data sheets for electric system . . . . . . . . . . . . . . . . . 11-53
Design parameter
Calculation Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Heat demand. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Designation
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Calculation of the system resistance and adjustment of the Desulphurisation module, component . . . . . . . . . . . 10-10
centrifugal pump to the service point . . . . . . . . 16-47
Desulphurisation system . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Centrifugal pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Diesel oil supply module, component
Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . 2-32, 2-35 Plant-related module, component . . . . . . . . . . . . . 8-7
Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Plant-related module, component 105 MW . . . . . 8-31
Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Plant-related module, component 55 MW . . . . . . 8-19
Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4, 10-5 Diesel oil supply system
Circular oil bath filter. . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Plant-related system . . . . . . . . . . . . . . . . . . . . . . . 7-7
Combustion air Plant-related system 105 MW . . . . . . . . . . . . . . . 7-38
Quality requirement . . . . . . . . . . . . . . . . . . . . . . . 3-43 Plant-related system 55 MW . . . . . . . . . . . . . . . . 7-22
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Contaminated process water treatment and discharge
Earthing, protection system
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Earthing system . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27 Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63
Control, monitoring, alarm system Touch, step voltages evaluation . . . . . . . . . . . . 11-66
Control system . . . . . . . . . . . . . . . . . . . . . . . . . 11-27 Electric motor
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 Procurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
General design . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
Index - i
F...F
component . . . . . . . . . . . . . . . . . . . . . . 6-52 Quality requirement of Gas oil, Diesel fuel (MGO) 3-39
Low temperature (LT) cooling water module, Quality requirements MDO. . . . . . . . . . . . . . . . . . 3-37
component . . . . . . . . . . . . . . . . . . . . . . 6-55
Viscosity-diagram (VT) . . . . . . . . . . . . . . . . . . . . . 3-41
Nozzle cooling water module, component . . . . . 6-57
Fuel oil filter module . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Engine 48/60 - related system
2-circuit radiator cooling system. . . . . . . . . . . . . . 5-8 Fuel oil module, component
Combustion air system . . . . . . . . . . . . . . . . . . . . 5-26 Engine 48/60 - related module, component . . . . 6-62
Index - ii
G...O
L O
Lighting small power system . . . . . . . . . . . . . . . . . . 11-69
Output
List of MAN B&W drwaings . . . . . . . . . . . . . . . . . . . 16-51 Engine 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Index - iii
P...S
Index - iv
T...W
Index - v
Index - vi
W...W